OPTIMIZE
PUMPING SYSTEMS
Diligent analysis, rigorous scrutiny
lead to longer system life
A U G U S T 2 01 4 PUMP-ZONE.COM
TURBOMACHINERY &
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SEALS & BEARINGS
Tips for Maximizing
PERFORMANCE
6 Considerations
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HYDRO INC. HEADQUARTERS CHICAGO, IL
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Hydro’s highly skilled pump improvement engineers provide complete reliability support for
your pump installation base, whether the equipment is recently commissioned or has been in
service for many years. Using the latest technology and our broad experience from the field,
we identify problems early – ensuring longer life and improved performance. And if you’re
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Hydro’s driving force is engineering. To help our customers maintain critical pump equipment, Hydro’s pump improvement engineers review the pump operating and maintenance history, provide a thorough on site inspection, and perform in-depth pump, driver and system testing. Our field engineers provide global support and are available for both routine and emergency situations.
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Hydro Reliability Services
From the Editor
T
his month we introduce an exciting, fresh, modern look to our logo and design that has been thoughtfully crafted to make the magazine easier for you to read and navigate. While the look has been updated, the content remains the same high-quality technical pumping information that you can’t i nd anywhere but in the pages of Pumps & Systems.It makes sense that we introduce this change with a focus on the increasingly vital topic of pump system optimization. Not long ago, the components of a pumping system were designed separately, purchased separately and maintained separately. h anks to advancements in technology and increased standards and awareness and the Hydraulic Institute’s
devel-opment of Pump Systems Matter, today the entire system is examined and modii ed to decrease life-cycle costs and save energy.
On average, industrial pumps operate at less than 40 percent ei ciency, and more than 10 percent of pumps run at less than 10 percent ei ciency. h is impacts the bottom line.
“h e cost to pump inei ciently is beyond your wildest imagination,” says Mike Pember-ton, ITT Performance Services Manager and Pumps & Systems Editorial Advisory Board member. “In the past several decades, pump ei ciency has only increased 3 percent by design. h e biggest advantage in increasing ei ciency is happening with automation and controls.” h e infrastructure is in place, but the question remains, “How do we optimize?”
h is year, Pumps & Systems published a three-part series from HI examining the Depart-ment of Energy’s pump ei ciency regulation changes (Jan.-March 2014, www.pump-zone. com). h e series describes how to reduce the burden on U.S. pump manufacturers and support the DOE’s ef orts to achieve energy savings and ei ciency improvements in the marketplace.
According to Pump Systems Matter, the most likely candidates for optimization are large systems, systems with high operating hours, problem systems and production-crit-ical systems. h e most common red-l ag symptoms are high energy costs, throttle valves that are generally closed, bypass valves/recirculation lines that are generally open, fre-quent failures or repair requirements, high operating noise levels (especially at the valve or pump), vibrations in the system and/or pump assembly, systems with multiple parallel pumps with the same number of pumps always operating, constant pump operation in a batch environment or frequent cycle batch operation in a continuous process, and systems that have undergone a change in function. Learn more by visiting www.pumps.org.
You can i nd a wealth of solutions by reading this month’s cover series, which begins on page 60. As always, pump ei ciency will be a major topic at the 43rd Turbomachinery and 30th Pump Symposia in Houston, Sept. 23 – 25. Visit the Pumps & Systems team at Booth 514, and tell us about your pump optimization success stories.
EDITORIAL
EDITOR: Michelle Segrest
[email protected] • 205-314-8279 MANAGING EDITOR: Lori K. Ditoro
[email protected] • 205-314-8269 SR. EDITOR, PRODUCTION & CONTENT MARKETING: Alecia Archibald
[email protected] • 205-314-3878 ASSOCIATE EDITOR: Michael Lambert
[email protected] • 205-314-8274 ASSOCIATE EDITOR: Savanna Lauderdale [email protected] • 205-278-2839 CONTRIBUTING EDITORS: Laurel Donoho, Joe Evans, Lev Nelik, Ray Hardee CREATIVE SERVICES
SENIOR ART DIRECTOR: Greg Ragsdale
ART DIRECTORS: Jaime DeArman, Melanie Magee WEB CONTENT EDITOR & WEB ADVERTISING TRAFFIC: Robert Ring
PRINT ADVERTISING TRAFFIC: Lisa Freeman [email protected] 205-212-9402
CIRCULATION
AUDIENCE DEVELOPMENT MANAGER: Lori Masaoay
[email protected] • 205-278-2840 ADVERTISING
NATIONAL SALES MANAGER: Derrell Moody [email protected] • 205-345-0784 Mary-Kathryn Baker [email protected] • 205-345-6036 Mark Goins [email protected] • 205-345-6414 Addison Perkins [email protected] • 205-561-2603 Vince Marino [email protected] • 205-561-2601 MARKETING ASSOCIATES: Ashley Morris [email protected] • 205-561-2600 Sonya Crocker [email protected] • 205-314-8276
PUBLISHER: Walter B. Evans, Jr. VP OF SALES: Greg Meineke VP OF EDITORIAL: Michelle Segrest CREATIVE DIRECTOR: Terri Jackson CONTROLLER: Tim Moore P.O. Box 530067 Birmingham, AL 35253 EDITORIAL & PRODUCTION 1900 28th Avenue South, Suite 200 Birmingham, AL 35209
205-212-9402 ADVERTISING SALES
2126 McFarland Blvd. East,. Suite A Tuscaloosa, AL 35404
205-345-0784 Pumps & Systems
is a member of the following organizations:
PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly Cahaba Media Group, 1900 28th Avenue So., Suite 200, Birmingham, AL 35209. Periodicals postage paid at Birmingham, AL, and additional mailing 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. ©2014 Cahaba Media Group, Inc. No part of this publication may be reproduced without the written consent of the publisher. The publisher does not warrant, either expressly or by implication, the factual accuracy of any advertisements, articles or descriptions herein, nor does the publisher warrant the validity of any views or opinions offered by the authors of said articles or descriptions. The opinions expressed are those of the individual authors, and do not necessarily represent the opinions of Cahaba Media Group. Cahaba Media Group makes no representation or warranties regarding the accuracy or appropriateness of the advice or any adver-tisements 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 submis-sion in any medium on multiple occasubmis-sions. You are free to publish your submissubmis-sion yourself or to allow others to republish your submissubmis-sion. Submissubmis-sions will not be returned. Volume 22, Issue 8.
Michelle Segrest with ITT’s Margaret Gan at the 2014 Offshore Technology Conference. The Pumps & Systems team returns to Houston for the Turbomachinery/Pump Symposia in September.
Editor, Michelle Segrest
Motors | Automation | Energy | Transmission & Distribution | Coatings
Features that make a difference:
̈"Dual rated for 60 Hz and 50 Hz @ 190-220/380-415 V
̈"Optimized ventilation system for cooler operation
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̈"Oversized diagonally split aluminum terminal box that exceeds IP55 requirements. (Ideal for easy installation and tough environments).
̈"Terminal box is rotatable in 90 degrees increments for easy installation
̈"AEGIS® ring inside (optional) to extend bearing life when used with VFDs
̈"IP55 ingress protection is standard
̈"Suitable for VFD operation per NEMA MG1 part 31.4.4.2
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Available in Open Drip and Totally Enclosed designs our WEG Rolled Steel line is the perfect example of these efforts. A product line with superior features that make a big difference for our customers.
4
AUGUST
This issue
60
STREAMLINED MOTORMANAGEMENT SYSTEM BOOSTS BIOMASS POWER GENERATION
BY Matthias Borutta
Phoenix Contact
Trusted gateway connections allow for system growth, ei ciency and consistent maintenance at Swedish paper mill.
64
INTELLIGENT MONITORING DELIVERS REAL-TIME PUMP PERFORMANCE DATABy Mike Pemberton
ITT Pro Services
An energy ei ciency and reliability study helped one plant save $1 million annually by avoiding downtime.
69
CLOSE INSPECTIONSOLVES HIGH THRUST BEARING TEMPERATURE PROBLEM
By Gary Dyson
Hydro Inc.
Careful analysis identii ed the issue with this multistage oil transfer pump.
73
SYSTEM SELECTION CRUCIALFOR LONG WASTEWATER PUMP LIFE
By Lars Bo Andersen
Grundfos Wastewater
Driving down investment, energy and maintenance costs translates into big savings throughout an installation’s lifetime.
76
REDUCER FITTINGS DECREASE PIPE SIZE TO PREVENT FAILUREBy Ross Mahaffey, Aurecon and Stefanus Johannes van
Vuuren, University of Pretoria Design of the pump inlet piping can protect overall operation.
COVER
S E R I E SPUMP SYSTEM
OPTIMIZATION
COLUMNS
PUMP ED 101
20
By Joe Evans, Ph.D.Pump Tech Inc.
h ree-Phase Voltage Variation & Unbalance
PUMPING PRESCRIPTIONS
26
By Lev Nelik, Ph.D., P.E.Pumping Machinery, LLC Simplify the Equipment Selection Process
PUMP SYSTEM IMPROVEMENT
28
By Ray HardeeEngineered Software, Inc. System Validation & Troubleshooting
GUEST COLUMNS
36
By Heinz P. Bloch, P.E.Pushing Fluid Machinery Leads to Failure
40
By Amin AlmasiEstimate Pump Installation Costs
DEPARTMENTS
84
EFFICIENCY MATTERS Smart Air Distribution Systems Upgrade Traditional AODD Pump Technology89
MAINTENANCE MINDERS 6 Rei nery Pump Maintenance Tips94
MOTORS & DRIVESh e Dif erences Between Submersible & Immersible Motors
98
SEALING SENSEExpansion Joint Selection Optimizes Piping Systems
102
HI PUMP FAQSUnderstand Specii c Speed & Disc Diaphragm Pump Coupling
64
60
Volume 22 • Number 8
© 2014 W
eatherfor
d. All rights r
eserved.
Your business can’t run
on a fabrication order.
PUMP AND FLUID SYSTEMS
Contact and collaborate with us at [email protected]
We deliver the pump you need without the wait.
0VSçVJEQVNQTLFFQZPVSCVTJOFTTNPWJOH'SPNDBVTUJDTUPDSVEFPJMBOEGSPN DSZPHFOJDUPCPJMJOH PVSQMVOHFSQVNQTEFMJWFSQPXFSBOESFMJBCJMJUZJOUIFPJMæFME GPPETFSWJDF NVOJDJQBM BOEDIFNJDBMJOEVTUSJFT UPOBNFBGFX 8IFOZPVPSEFSB8FBUIFSGPSEQSPEVDUJPOQVNQ ZPVHFUNPSFUIBOBGBCSJDBUJPOPSEFS 0VSFYUFOTJWFTUPDLPGQVNQTsJODMVEJOHUIPTFNBEFGSPNQSFNJVNNBUFSJBMT TVDIBTEVQMFYTUBJOMFTTTUFFM OJDLFMBMVNJOVNCSPO[F BOEDBSCPOTUFFMsFOTVSFT UIBUZPVHFUUIFQVNQZPVOFFE OPUBGBCSJDBUJPOPSEFS
Pressure ratings from
500 psi
(3.6 MPa)to
10,000 psi
(207 MPa)Flowrates from
1 to 1,680 gpm
Power ratings from
2
to
700 hp
Formation Evaluation
|
Well Construction
|
Completion & Stimulation
|
Production
6
This issue
SPECIAL
S P E C I A L S E C T I O N
THOMAS L. ANGLE, P.E., MSC, Vice President Engineering, Hidrostal AG
ROBERT K. ASDAL, Executive Director, Hydraulic Institute
BRYAN S. BARRINGTON, Machinery Engineer, Lyondell Chemical Co.
KERRY BASKINS, VP/GM, Milton Roy Americas WALTER BONNETT, Vice President Global Marketing, Pump Solutions Group R. THOMAS BROWN III, President, Advanced Sealing International (ASI) CHRIS CALDWELL, Director of Advanced Collection Technology, Business Area Wastewater Solutions,
Sulzer Pumps, ABS USA
JACK CREAMER, Market Segment Manager – Pumping Equipment, Square D by Schneider Electric
BOB DOMKOWSKI, Business Development Manager – Transport Pumping and Amusement Markets/Engineering Consultant, Xylem, Inc., Water Solutions USA – Flygt
DAVID A. DOTY, North American Sales Manager, Moyno Industrial Pumps
WALT ERNDT, VP/GM, Crane Pumps & Systems JOE EVANS, Ph.D., Customer & Employee Education, PumpTech, Inc.
RALPH P. GABRIEL, Chief Engineer – Global, John Crane
BOB LANGTON, Vice President, Industry Sales, Grundfos Pumps
LARRY LEWIS, President, Vanton Pump and Equipment Corp.
TODD LOUDIN, President/CEO North American Operations, Flowrox Inc.
JOHN MALINOWSKI, Sr. Product Manager, AC Motors, Baldor Electric Company, A Member of the ABB Group
WILLIAM E. NEIS, P.E., President, Northeast Industrial Sales
LEV NELIK, Ph.D., P.E., APICS, President, PumpingMachinery, LLC
HENRY PECK, President, Geiger Pump & Equipment Company
MIKE PEMBERTON, Manager, ITT Performance Services
SCOTT SORENSEN, Oil & Gas Automation Consultant & Market Developer, Siemens Industry Sector
ADAM STOLBERG, Executive Director, Submersible Wastewater Pump Association (SWPA)
JERRY TURNER, Founder/Senior Advisor, Pioneer Pump
KIRK WILSON, President, Services & Solutions, Flowserve Corporation
JAMES WONG, Associate Product Manager – Bearing Isolator, Garlock Sealing Technologies
EDITORIAL
ADVISORY BOARD
2
FROM THE EDITOR
8
READERS RESPOND
10
NEWS80
TRADE SHOW COVERAGE118
PRODUCT PIPELINE124
PUMP USERS MARKETPLACE128
PUMP MARKET ANALYSISSEALS & BEARINGS
42
CANNED MAGNETIC BEARINGS MINIMIZE CORROSION IN OIL & GAS PROCESSINGBy Richard R. Shultz
Waukesha Magnetic Bearings Safely immerse motor compressors in process gas without risking costly damage.
45
THE RIGHT SEAL & LUBRICANT COMBINATION CAN PREVENT BEARING CONTAMINATIONBy James Wong
Garlock Sealing Technologies Lip and labyrinth seals provide protection in harsh oil and gas applications.
PRACTICE &
OPERATIONS
106
ENERGY EFFICIENT VERTICAL TURBINE PUMPS PROMOTE SUSTAINABLE MINING EFFORTSBy Petar Ostojic
Neptuno Pumps
h e computational l uid dynamics process advances highly ei cient pump designs for dii cult applications.
110
SPECIFIC PUMP & VALVEFEATURES SERVE LIQUEFIED NATURAL GAS APPLICATIONS
By Gobind Khiani
Fluor Canada Ltd.
LNG benei ts have increased the demand for this cleaner burning fuel and associated production and distribution equipment.
114
DEWATERING PUMPS HANDLE SAND SLURRIES IN POST-HURRICANE RECOVERYBy Mike Bjorkman
BJM Pumps
Reconstruction and infrastructure upgrades require pumps from durable materials.
50
SELECT SEALS THAT MEET THE CHEMICAL CHALLENGES OF HPLC PUMPSBy Jerry Zawada
Trelleborg Sealing Solutions Abrasive processing and wide temperature range are some of the pumping dii culties for high-performance liquid chromatography.
54
TREATED CARBIDE SURFACESENHANCE RUNNING PERFORMANCE
By Mark Slivinski
Carbide Derivative Technologies Inc. h is technology self-lubricates, reduces friction, and performs in wet or dry operating conditions.
Borets Equipment is a HPS horizontal
multistage pump manufacturer that
provides pumping solutions with
exceptional customer service.
H
O R I Z O N T A LP
U M P I N GS
Y S T E M SSERVICE
SERVICE
Reliable. Quality. Modular.
Horizontal Pumping System (HPS) by Borets Equipment.
Cost-competitive and customizable for your specific application, the HPS equipment requires less inventory and delivery time than traditional API 610 multistage, vertical turbine can and reciprocating pump equipment.
Engineered for reliability, modularity, and quick replacement of components, the HPS pump has a lower life cycle cost, thanks to minimized downtime and low maintenance requirement. The result is a reliable, flexible and innovative pumping system.
You provide the application, we’ll provide the Pump Power and Service.
RELIABLE – FLEXIBLE – INNOVATIVE
w w w . b o r e t s . c o m / H P S Low Pro Design
8
READERS RESPOND
“A Salute to
Frank Weis,”
From the Editor
MARCH 2014
I was sent your article while I was at the American Water Works Association
conference in Boston. h ank you so much for writing this and sharing some of your thoughts on Frank.
I just wanted to share more with someone, so I decided to give you more background. Frank was my i rst boss when I joined Smith and Loveless in 1983, fresh out of graduate school. I won’t go into all the engineering details I learned from just watching him but wanted to share the personal side.
I worked for, with and shared lunch with Frank many days over my next six years of employment. He treated everyone the same, from the janitor to the president of the company. He was friendly to all, had a great sense of hu-mor, enjoyed pulling pranks on select employees, and I never, ever saw him be upset or have a bad day!
We were both alumni of the Univer-sity of Missouri, and he loved sports, had coached his kids baseball and bas-ketball teams and loved to talk sports of all kinds. He shared his knowledge with any that asked, but he was the most humble guy I have ever known.
He went about his work with a quiet determination and knew exactly what he was trying to achieve, even if it didn’t i t with the views of management at the moment! He had an amazing inl uence on my professional and personal life, and I tell sto-ries related to him almost every week. I left the company in 1989 and moved to Degremont in Virginia, but his inl uence had more impact on me than anyone I have worked with since that time.
I am now back in Kansas City and was fortunate enough to attend the 50th anniversary of Frank’s work at Smith and Love-less in 2004. As was typical for Frank, he didn’t want it to be a big deal, so the ceremony was held on the shop l oor. Several former employees attended, many who had long since retired!
I knew then how unique Frank was but have understood this even more in the years that have passed. As great a man as he was from the engineer-ing and invention side, he was an even better man overall. h e world was a better place for the time he was here and for all the individuals that got to know him.
Andy Mitchell
Director, Business Development Metawater USA, Inc.
Pumps & Systems Editor Michelle
Segrest responds:
h ank you for reading my column about Frank Weis (www.pump-zone.com/blog/ salute-frank-weis) and for responding with these nice comments. h e additional insight into the life of this legendary pump innovator is greatly appreciated. Frank Weis was well respected in the pump industry and will be missed by all who knew him.
READERS
respon
D
To have a letter considered for Readers Respond, please send it to Michael Lambert, [email protected].
10
NEWS
NEW HIRES,
PROMOTIONS & RECOGNITIONS
LARRY LEWIS, VANTON PUMP
HILLSIDE, N.J. (July 10, 2014) – The Board of Directors of the Vanton Pump and Equipment Corp. voted to name Larry Lewis as the company’s president and chief executive offi cer. Lewis has served as Vanton’s president since 2010. Vanton Pump and Equipment Corp. supplies chemically inert, thermoplastic pumps and systems that solve fl uid containment, dosing and transfer problems. www.vanton.com
DAVID BOEZI, DANFOSS
BALTIMORE (June 24, 2014) – Danfoss hired David Boezi as senior director, strategy and global platforms. In this role, Boezi will help Danfoss tailor its high-effi ciency compressor portfolio to respond to changing customer needs that are being infl uenced by new refrigerant and energy-effi ciency regulations. Danfoss supplies technologies that meet the growing need for food
supply, energy effi ciency, climate-friendly solutions and modern infrastructure. www.danfoss.com
DICK SHEAR, MULTI W SYSTEMS
EL MONTE, Calif. (June 20, 2014) – Multi W Systems Inc. announced the appointment of Dick Shear as general sales manager. Multi W Systems manufactures and distributes pump systems, electrical controls and related engineered machinery. www.multiwsystems.com
PAMELA HENRY, WEF
ALEXANDRIA, Va. (June 19, 2014) – The Water Environment Federation (WEF) promoted Pamela Henry to the position of deputy executive director. Having been with WEF for more than 25 years, Henry is a seasoned leader who will oversee a number of key organizational programs including WEFTEC operations and exhibitions, advertising and sponsorships, marketing, communications and creative services, human
resources, and facilities management. WEF is a not-for-profi t technical and educational organization of 36,000 individual members and 75 affi liated Member Associations representing water quality professionals around the world. www.wef.org
CHUCK HULL, 3D SYSTEMS
ROCK HILL, S.C. (June 17, 2014) – 3D Systems announced that Chuck Hull received the 2014 European Inventor Award in the non-European countries category in recognition of his invention of the three-dimensional (3-D) printing technology Stereolithography. Presented
annually by the European Patent Offi ce, the award honors inventors who made signifi cant contributions to technological progress and the advancement of society. 3D Systems provides 3-D printing centric design-to-manufacturing solutions including 3-D printers, print materials and cloud-sourced on-demand custom parts for professionals and consumers in materials including plastics, metals, ceramics and edibles. www.3dsystems.com
EDWARD CRANER, HOLT CAT
SAN ANTONIO, Texas (June 16, 2014) – HOLT CAT named Edward Craner senior vice president, strategy and marketing. In his new role, Craner will continue to lead and develop corporate strategy, marketing and customer experience initiatives to support sales growth. HOLT CAT sells, rents and services Caterpillar machines, engines, generator sets and trucks. www.holtcat.com Edward Craner Larry Lewis David Boezi Dick Shear Pamela Henry
SPOTLIGHT
PUMPS & SYSTEMS LAUNCHES
MIDDLE EAST/NORTH AFRICA MAGAZINE
BIRMINGHAM, Ala. (July 2, 2014) – Pumps & Systems, the leading magazine for pump users worldwide for more than 20 years, expands its international coverage of powerful technical pumping information to the Middle East/North Africa region. The premier issue of Pumps & Systems MENA will launch in early October 2014. It also will be distributed at the Pumps & Systems booth Nov. 10, 2014, at the Abu Dhabi International Petroleum Exhibition & Conference, the region’s leading conference for oil and gas professionals. Pumps & Systems MENA will publish bimonthly in 2015 following the October 2014 launch and will cover case studies and technical information in the following industries:
• Oil & gas (upstream and downstream) • Water & wastewater
• Power generation • Food & beverage processing • Building services
• Chemical, petrochemical & refi nery
The regular editorial coverage will also include strategic and insightful market data from respected market research analysts Frost & Sullivan. The magazine will be supported digitally with a website,
www.pump-zone.com/mena, and a twice-per-month e-newsletter, Pump Users Digest MENA. Subscribe to the e-newsletter and magazine at www.pump-zone.com/mena.
pu mp-z o ne .c o m | Au g us t 2 0 1 4
11
HENRI V. AZIBERT, FSA
WAYNE, Pa. (June 13, 2014) – The Fluid Sealing Association (FSA) announced the appointment of Henri V. Azibert as its new technical director. Pumps & Systems has partnered with the FSA for 10 years and posted exclusive
“Sealing Sense” articles in every issue. Azibert will now coordinate these articles, which provide the readers of Pumps & Systems with crucial technical information about mechanical seals, compression packing, gaskets, expansion joints, sealing components and molded packing. Azibert has also joined the prestigious Pumps & Systems Editorial Advisory Board. FSA is an international trade association. Members are involved in the production and marketing of virtually every kind of fl uid sealing device in the world. www. fl uidsealing.com
JOHN DONAHUE, AWWA
BOSTON (June 12, 2014) In a spirited event at the conclusion of the American Water Works Association’s Annual Conference and Exposition in Boston, John Donahue, chief executive offi cer of North Park, Illinois,
Water District, accepted the ceremonial AWWA gavel and began his term as president. The gavel passing ceremony was the culmination of a fi ve-day conference that drew more than 11,000 water professionals and water technology providers to Boston. The American Water Works Association is the largest nonprofi t, scientifi c and educational association dedicated to managing and treating water. www.awwa.org
GREG HEWITT, BALDOR ELECTRIC COMPANY
FORT SMITH, Ark. (June 9, 2014) – Baldor Electric Company promoted Greg Hewitt to mounted bearing engineering manager. In this role, he will be responsible for all mounted bearing
product-related engineering and will manage the product development team in Greenville, South Carolina.
Baldor Electric Company markets, designs and manufactures industrial electric motors, drives and mechanical power transmission products. www.baldor.com
Henri V. Azibert
John Donahue
Greg Hewitt
5300 Business Drive, Huntington Beach, CA 92649 USA 714-893-8529 • [email protected]
www.blue-white.com • www.proseries-m.com
A
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IP IP IP IP IP IP IP IP IP IP IP IP IP IP IPP666666666666666666666666666666666666 Three Models Available with Feed Rates Ranging from 0.1 GPH/.03 LPH to 158 GPH/600 LPH. Smooth, Quiet and Eicient Pumping Action. Brushless Variable Speed Motor. Terminal Blocks in Junction Box for Remote Connections. Patented Tube Failure Detection, Patented Safety Switch, Patented Method for Extended Tube Life. One or Two Pump, Engineered Skid System is Available.
FLEX-PRO
®Peristaltic Metering Pump
N
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NEM NEM NEM NEM NEMEMEMEMEMMA 4A 4A 4A 4A 4A 4A 4A 4A 4A 4A 4A 4A 4A 4A 44XXXXXXXXXXXXXXXXX W W W WAS WAS WAS WAS WAS WAS WAS WASWASH DH DH DH DH DH DH DH DH DH DDDOWNOWNOWNOWNOWNOWNOWOWNOWNOWNOWNOWNOOWNWNWN
Standard 61 Sonic-Pro S4 accurately measures
flow using the Transit Time method. It can be used with water containing low levels of chemicals and up to 5% particulates. Optional communication protocols include Industrial Ethernet, Profibus and Modbus.
Ultrasonic Transit Time operation.
Optional factory configuration for easy installation.
Inline spool piece (inline fitting). 4-20mA and Pulse Outputs. Special low power mode permits
operation with battery for limited
functions. Advanced communication. Data logging
SONIC-PRO
®Ultrasonic Flowmeter
ci rc le 1 2 6 o n c a rd o r v is it p sf re ei n fo .c o m12
NEWS
CHARLES WHISMAN, CH2M HILL
DENVER (June 5, 2014) – CH2M HILL announced that Charles Whisman joined the fi rm as vice president and U.S. oil and gas operations manager for the environment and nuclear market. CH2M HILL provides consulting, design, design-build, operations and program management for government, civil, industrial and energy clients. www.ch2m.com
DAVE MORROW, OPW
LEBANON, Ohio (June 6, 2014) – OPW announced the promotion of Dave Morrow to director of product management for its Chemical & Industrial business unit. Before this appointment, he was product
manager for OPW Engineered Systems. OPW Engineered Systems provides loading and coupling systems for the safe and effi cient loading and unloading of critical hazardous fl uids. www.opw-es.com
JOHN MOLNAR,
ARMSTRONG FLUID TECHNOLOGY
TORONTO (June 5, 2014) – Armstrong Fluid Technology announced that John Molnar joined the company as technical sales representative, commercial and engineering. In his new role, he will develop and grow relationships with engineers, contractors and service dealers in the
Ontario territory. His main focus will be working with standard and confi gured building
products and design envelope solutions. Armstrong Fluid Technology designs, engineers and manufactures integrated solutions within the building-oriented fl uid-fl ow equipment industry. www. armstrongfl uidtechnology.com
Charles Whisman Dave Morrow
John Molnar YASKAWA AMERICA, INC. acquired Solectria
Renewables, LLC July 17, 2014 GE acquired Monsal July 1, 2014
ACOEM acquired FIXTURLASER June 30, 2014
DES-CASE acquired ESCO s sight glass product line
June 19, 2014
BLACKHAWK SPECIALTY TOOLS acquired Trinity Tool Rentals
June 10, 2014
FRANKLIN ELECTRIC acquired Bombas Leão S.A.
June 9, 2014
NATIONAL PUMP COMPANY acquired Bayou City Pump
June 3, 2014
MERGERS & ACQUISITIONS
pu mp-z o ne .c o m | Au g us t 2 0 1 4
13
AROUND
THE INDUSTRY
EXONE to Open Combined Production Service Center in Italy
NORTH HUNTINGDON, Pa. – (June 19, 2014) The ExOne Company announced the planned opening of a new combined production service center and machine sales center in the Lombardy region of Italy. Said Omar, most recently ExOne’s European sales director, will be ExOne Italy’s managing director. ExOne provides 3-D printing machines and printed products, materials and other services to industrial customers. www.exone.com WEATHERFORD Opens Integrated Colombia Laboratory
BOGOTA, Colombia (June 13, 2014) Javier Betancourt, the president of Agencia Nacional de Hidrocarburos – Colombia, marked the offi cial opening of the new Weatherford lab in
Bogota, Colombia, during a ribbon-cutting ceremony. This new facility provides traditional core and fl uid analysis combined with specialty services such as shale rock properties, geochemistry, wellsite geosciences, frac fl uids, drilling fl uids and elastomer testing for progressive cavity pumps.
Weatherford International provides oilfi eld products and services across the drilling, evaluation, completion, production and intervention areas. www.weatherford.com
DYNAMIC INDUSTRIES INTERNATIONAL LLC Receives SAGIA License
HOUSTON (June 11, 2014) – Dynamic Industries International LLC
announced that its Saudi Arabian offi ce received its license to operate from the Saudi Arabian General Investment Authority (SAGIA). Dynamic Industries International LLC provides full-service fabrication, construction
and maintenance services to the offshore worldwide markets. www. dynamicind.com
SIEMENS Invests in Software Grants RICHMOND, Va. (June 5, 2014) Siemens announced more than $1 billion of in-kind software grants for manufacturing programs at community colleges and universities in Virginia. The series of in-kind grants was established as a result of an industry need for skilled workers and is designed to support the state’s largest industrial employer, Newport News Shipbuilding, a division of Huntington Ingalls Industries, and other companies with local ties such as Rolls-Royce. Siemens Industry Sector supplies products, solutions and services for industrial customers. www.siemens.com
14
NEWS
AROUND
THE INDUSTRY
ABB TURBOCHARGING Inaugurates Denmark Facility BADEN, Switzerland (June 4, 2014) ABB Turbocharging announced a ceremony that celebrated the opening of a new service facility in Fredericia,
Denmark. The ceremony also marked the completion of the amalgamation of its activities in Norway, Denmark and Sweden into a single Local Business Unit. ABB Turbocharging Scandinavia comprises service stations in Oslo and
Bergen in Norway, Göteborg in Sweden, and the new central workshop for Denmark in Fredericia. Additionally, the company has two service engineers and a sales team stationed in Copenhagen. This geographical footprint will soon be furthered by a new service point in Tromsø, Norway. ABB Turbocharging manufactures and services turbochargers. www.abb.com GRUNDFOS, PUB to Collaborate on Water Technologies
SINGAPORE (June 3, 2014) – Pump manufacturer Grundfos and PUB, Singapore’s national water agency, have signed a memorandum of understanding (MOU) to collaborate on the development of water technologies and solutions. The MOU sets out to support PUB in its mission to ensure a robust and sustainable water supply for Singapore and to continuously explore new technologies and solutions to meet current and future water challenges. PUB is a statutory board under the Ministry of the Environment and Water Resources. It is the water agency that manages Singapore’s water supply, water catchment and used water. www.pub.gov.sg Grundfos is a pump manufacturer, offering water solutions with modular, energy effi cient and intelligent products and services that can be tailored for industrial, water utility, water supply, urban and agricultural applications. www.grundfos.com
EPA Proposes Guidelines to Cut Carbon Pollution WASHINGTON (June 2, 2014) – At the direction of President Obama and after an unprecedented outreach effort, the U.S. Environmental Protection Agency (EPA) released the Clean Power Plan proposal, which for the fi rst time cuts carbon pollution from existing power plants, the single largest source of carbon pollution in the U.S. The proposal aims to protect public health, move the U.S. toward a cleaner environment and fi ght climate change while supplying Americans with reliable and affordable power. By 2030, the steps that the EPA is taking will: • Cut carbon emission from the power
sector by 30 percent nationwide
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NEWS
AROUND
THE INDUSTRY
below 2005 levels, which is equal to the emissions from powering more than half the U.S. homes for one year • Cut particle pollution, nitrogen
oxides and sulfur dioxide by more than 25 percent
• Avoid up to 6,600 premature deaths, up to 150,000 asthma attacks in children, and up to 490,000 missed work or school days—providing up to $93 billion in climate and public health benefi ts
• Shrink electricity bills roughly 8 percent by increasing energy effi ciency and reducing demand in the electricity system
EPA’s mission is to protect human health and the environment. www.epa.gov
ABAKAN Increases Direct Ownership in MesoCoat MIAMI (June 2, 2014) – Abakan Inc. announced that it has increased its ownership position in its majority owned subsidiary, MesoCoat Inc., to a 87.5 percent direct and 89.9 percent direct and indirect ownership. The increase is the result of converting an additional $6.2 million in MesoCoat investment into equity and exchanging 21 percent of ownership in Powdermet for 65.3 percent of Powdermet’s shares of MesoCoat. Abakan develops, manufactures and markets advanced nanocomposite materials, fabricated metal products and metal composites for applications in the oil and gas, petrochemical, mining, aerospace and defense, energy, infrastructure, and processing industries.
www.abakaninc.com
WEF, IWA Sign Water Management MOU ALEXANDRIA, Va. (May 27, 2014) The Water Environment Federation (WEF) and the International Water Association (IWA) signed a memorandum of understanding (MOU) intended to accelerate joint work to grow and disseminate water knowledge and to serve and advance the global water profession. WEF is a not-for-profi t technical and educational organization representing water quality professionals around the world. www.wef.org IWA is a global network of water professionals that spans the continuum between research and practice, covering all facets of the water cycle. www.iwahq.org
To have a news item considered, please send the information to Savanna Lauderdale, [email protected].
18
NEWS
EVENTS
PumpTec-USA Sept. 10 – 11, 2014
Georgia World Congress Center Atlanta, Ga. 770-310-0866 www.pumpconference.com Turbomachinery/ Pump Symposia Sept. 23 – 25, 2014 George R. Brown Convention Center Houston, Texas 979-845-7417 pumpturbo.tamu.edu WEFTEC Sept. 27 – Oct. 1, 2014 New Orleans Morial Convention Center New Orleans, La.
www.weftec.org
International Association of Amusement Parks and Attractions (IAAPA) Nov. 18 – 21, 2014
Orange County Convention Center Orlando, Fla.
703-836-4800
www.iaapa.org
PumpTec-Israel Dec. 3 – 5, 2014
Jointly with Electricity-Israel 2014 Conference Eilat, Israel 770-310-0866 www.pumpingmachinery. com/conference_2014_Israel/ conference_2014_Israel.htm POWER-GEN International Dec. 9 – 11, 2014
Orange County Convention Center Orlando, Fla.
918-831-9161
www.power-gen.com
NGWA Expo & Annual Meeting Dec. 9 – 12, 2014
Las Vegas Convention Center Las Vegas, Nev.
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I
n my July 2014 column, I demonstrated that three-phase voltage variation can signii cantly af ect several alternat-ing current (AC) motor character-istics. If that variation is large, it can also reduce motor life. Voltage unbalance can be an even bigger problem and is one of the major causes of premature motor failure. A relatively small unbalance of just 2 percent can reduce expected insulation life by half.Calculating Voltage Unbalance
Unlike voltage variation, unbal-anced voltage occurs when the three phases are not at the same voltage. An example of perfectly balanced phase voltage is L1/L2 = 460 V, L2/L3 = 460 V and L3/L1 = 460 V. h e average voltage is 460 volts.
An example of unbalanced phase voltage is L1/L2 = 462 V, L2/L3 = 468 V and L3/L1 = 450 V. Again, the average voltage is 460 V, but the unbalance is 2.2 percent. Voltage unbalance is calculated by the fol-lowing equation:
Percent unbalance = 100 x (maximum voltage deviation from average / average voltage)
In the example above, the maximum voltage deviation from the average voltage is 10 V (460
minus 450). Motors from member companies of the National Electri-cal Manufacturers Association (NEMA) are designed to tolerate no more than 1 percent of voltage unbalance.
Why does voltage unbalance shorten motor life? One percent of voltage unbalance can result in 6 to 10 percent of current unbalance. h e phase with the lowest voltage exhibits the highest current, which increases the operating tempera-ture of the winding serviced by that phase. It will also increase the
over-all operating temperature of the motor. Figure 1 shows the increase in operating temperature versus voltage unbalance. As shown, an unbalance of just 3 percent can increase operating temperature by almost 20 percent. At 5 percent unbalance, operating temperature will increase by 50 percent. Temperature Rating & Insulation Class
Motor operating temperature is the sum of the ambient temperature surrounding the motor and the
Three-Phase Voltage
Variation & Unbalance
Last of Two Parts
ByJoe Evans, Ph.D.
Pump Tech Inc., P&S Editorial Advisory Board
Figure 1. Overheating because of voltage unbalance
temperature rise due to the motor load. h e temperature rise is usu-ally measured using the resistance method. Each insulation class has a specii c temperature rating. For example, Class F is rated at 155 C (311 F). h e temperature rating is the maximum operating tempera-ture allowed in order to meet an average insulation life of 20,000 hours.
Of that rating, 10 C is reserved for the hot spot allowance. h e resistance method measures the average temperature rise in the sta-tor windings, but at some places— such as the stator slots—the temperature can be higher than the average measurement. h e hot spot allowance is reserved to protect these areas. h is reduces the actual operating temperature (ambient plus measured average) to 145 C. For every 10 degrees over 145 C, insulation life is reduced by half. For every 10 degrees below 145 C, insulation life doubles.
Suppose a motor with Class F insulation operates at an ambient temperature of 40 C. h e mea-sured temperature rise at full load is 90 C. h erefore, the operating temperature is 130 C. h e expected insulation life would be about 50,000 hours or about 2.5 times the life at 145 C. But at 3 percent phase voltage unbalance, the oper-ating temperature increases by 19 percent (155 C) and insulation life is reduced by 50 percent.
Image 1 shows the windings of a motor that failed because of high voltage unbalance. When a motor loses one phase (single phasing), the other two phases have to carry the entire load. As a result, two sets
Voltage unbalance is one of the major causes of premature motor
failure. A relatively small unbalance of just 2 percent can reduce
expected insulation life by half.
21
pu mp-z o ne .c o m | Au g us t 2 0 1 4
21
of phase windings are destroyed, and the one that lost power is unharmed.
Motor Phase Loss & Failure
In the case of unbalance, the winding with the highest current fails and, usually, the other two are still functional. In the motor shown in Image 1, one of the phases has failed, one is normal and the third is beginning to show the ef ect of higher temperature. Measuring voltage unbalance and i xing the cause are much less costly than having it diagnosed in a motor shop. See “Pump Ed 101” in the July 2008 issue of Pumps & Systems for instructions on diagnosing the cause of unbal-anced voltage.
Although correcting voltage unbalance is always best, a few rules can allow operation in unbalanced applications. For example, if the leg with the highest current is under the nameplate full load amperage (FLA), it will safely operate. If
Image 1. Windings of a motor that failed because of high voltage unbalance.
(Image courtesy of EASA)
22
PUMP ED 101
23
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it is above nameplate FLA but still within the service factor (SF), it may still safely operate. As a rule, if the high current leg is less than 10 percent higher than the average current, it will probably safely operate.
A less desirable alternative is to derate the motor’s nameplate horsepower. NEMA suggests derating horsepower to 75 percent of nameplate at an unbalance of 5 percent. At 4 percent unbalance,
it is derated to 82 percent. At 3 percent, it is derated to 88 percent, and at 2 percent, it is derated to 95 percent.
In addition to reduced insulation life, unbalanced voltage can also increase electrical costs by decreas-ing motor ei ciency. At 1 percent unbalance, ei ciency remains at the nameplate nominal ei ciency. However, at 3 percent unbalance, actual motor ei ciency can be re-duced by 2 percentage points.
Joe Evans is responsible for customer and employee education at PumpTech Inc., a pump and packaged system manufacturer and distributor with branches throughout the Pacifi 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 col-umns, drop him an email.
In addition to reduced insulation life, unbalanced voltage
can also increase electrical costs by decreasing motor effi ciency.
24
PUMP ED 101
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W
hen the pump selection process starts, the required l ow of the is often the only known variable for an application. For example, a system must move 2,000 gallons per minute (gpm) from a holding tank to another tank or process.What size pump do should be installed? h e size and pressure of the piping and the power of the mo-tor must also be determined. h is column helps explain how to make these decisions.
Pump & Piping Size h e longer the piping, the more pressure its internal friction will generate. A good way to pick a pipe size is to calculate its diameter from an empirical but simple starting formula. h is will help establish an approximate range. Pipe velocity is usually between 5 and 10 feet per second (ft/sec).
h e smaller a pipe’s diameter, the faster l uid l ows through it. h e larger the pipe, the more expensive it is. Also, l owing too slowly may cause particulate matter to settle and clog the line, but l owing too quickly will wear the pipe. h e 5 to 10 ft/sec range is usually a good starting point. Equation 1 can used for a more accurate calculation.
V = Q x 0.321 / A
Equation 1 Where:
V = velocity in ft/sec Q = l ow in gpm
A = pipe area in square inches (in2)
In our example, 5 = 2,000 x 0.321 / A A = 2,000 x 0.321 / 5 = 128.4 in2 pipe area, or 12.8 inch
diameter
h is diameter can round to a 12-inch pipe with a velocity of slightly more than 5 ft/sec.
h e next step is to i gure out the amount of pressure in the system if the pump is 5,000 feet away from the process’discharge. h is determination is more complicated because some hydraulic informa-tion is needed. Several opinforma-tions can provide this information: come to class, consult a piping friction loss chart or take my word for it that the losses for cold water at 2,000 gpm in a 12-inch, 5,000-foot pipe are about 70 feet.
With the l ow and head deter-mined, the motor can be sized (see Table 1). Also, an online Ei ciency Estimator, which can be found at www.mj-scope.com/pump_tools/ pump_ei ciency.htm, of ers useful formulas.
To handle the process specii ca-tions, a single-stage pump was se-lected. h e Ei ciency Estimator cal-culated that a 42-horsepower and 84.5-percent pump ei ciency can be expected from a typical pump. h is number can be coni rmed with quotes from pump distributors.
h e Ei ciency Estimator also suggests an impeller size of 9.77 inches. h is measurement is a good way to roughly verify the appropri-ate sizes of existing pumps. h is process provides useful preliminary information for pump selection. Motor Size
A 1,800-rpm motor speed was selected for this process because it is one of the most common motor speeds in the U.S. h e horsepower recommendation can be rounded to select a 50-horsepower motor. If the pump is expected occasionally to operate outside the curve, choosing a 75-horsepower leaves a margin of safety.
Simplify the Equipment
Selection Process
By Lev Nelik, Ph.D., P.E.
Pumping Machinery, LLC, P&S Editorial Advisory Board
Table 1. Sizing motors during pump selection
(Graphics courtesy of the author.)
US Units
Pump l ow (gpm) 2,000
Total pump head (ft) 70
Specii c gravity (SG) 1.00
Number of stages 1
Speed (rpm) 1,800
Header per stage (ft) 70
Impeller diameter (in) 9.77
Specii c speed U.S. (Ns) 3,326
Specii c speed metric (ns) 64.5
Specii c speed universal (Os) 1.22
Ei ciency (%) 84.5
Power (hp) 42
NPSHA Calculation h e suction side must be consid-ered. My last few columns dis-cussed pump suction performance. For example, I discussed how the system af ects the operation and the relationship between the l ow (as a percent of the best ei ciency point) and suction recirculation. Many end users question how much net positive suction head available (NPSHA) they need.
If a pump has too little NPSHA, it could experience suction problems. Too much NPSHA leads to higher construction costs. Users must i nd the right balance. My next column will describe in detail the beginning of the selection process. For those interested in how to calculate the piping losses estimated (70 feet of head), my Pump School training covers this in-depth.
Dr. Nelik (aka “Dr. Pump”) is president of Pumping Machin-ery, LLC, an Atlanta-based fi rm specializing in pump consulting, training, equipment trouble-shooting and pump repairs. Dr. Nelik has 30 years of experience in pumps and pumping equip-ment. He may be reached at
pump-magazine.com.
If a pump has too little NPSHA, it could experience suction
problems. Too much NPSHA leads to higher contruction costs.
Users must fi nd the right balance.
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PUMP SYSTEM IMPROVEMENT
I
n the previous article calcu-lating the cost of elements in a piping system (Pumps & Systems, July 2014), the energy consumed and power cost balanced exactly to demonstrate the process. Seldom is life that exact. In the real-world plant, instruments are subject to inaccuracy, pumps may be worn, estimates may be of or the full system may not be accurately represented in the design documents.h is month’s article demon-strates how cross-validating the calculated results can ensure the energy cost balance sheet accurately rel ects system operation.
h e key to validating the results is to use multiple means for arriv-ing at the operatarriv-ing cost of each item in the energy cost balance sheet. If the energy cost balance sheet does not add up, trouble-shooting skills need to be employed to discover the reason for the dif-ference.
h is article will continue to use the example piping system presented in previous articles (see Figure 1).
Prioritizing the System h e pump elements provide all the energy that enters the system. h at energy is then consumed by the system’s process and control elements.
If the energy cost balance sheet does not balance, operators should begin looking for the source of the problem. h e major energy users
in the system should be examined, and operators should i nd meth-ods to cross-validate the initial estimates.
Pump Performance In the example, the pump’s l ow rate was determined using the
manufacturer’s pump curve. With a known l ow rate, the pump ef-i cef-iency can be determef-ined from the curve.
Because the pump ei ciency is used in all energy cost calculations, ensuring the accuracy of the value is critical.
System Validation
& Troubleshooting
By Ray Hardee Engineered Software, Inc.
Figure 1. Drawing of sample piping system
(Article graphics courtesy of the author.)
Figure 2. An example showing the effect internal leakage has on pump performance. Because of internal leakage, the installed pump is not operating as designed.
pu mp-z o ne .c o m | Au g us t 2 0 1 4
29
Inaccuracies can occur in real-life operating conditions. For example, if the pump has a worn impeller and excessive internal leakage, it no longer rel ects the pump curve’s operation.
Figure 2 shows a pump curve for the process pump along with an example of the ef ect that excessive internal leakage can have on the pump curve.
Using the calculated head dif-ference of 235 feet (ft), the worn impeller gives a l ow rate of less than the 4,000 gallons per minute (gpm) used in the previous energy system balance.
In addition, the ei ciency of a worn impeller would dif er from the manufacturer-supplied test curve.
h is would result in inaccurate power consumption and operation costs calculations.
Operators have other options to determine the l ow rate through the pump, including portable ultrasonic l ow meters.
h ese meters provide a reason-ably accurate l ow measurement in a pipeline without physically changing the piping system.
If the observed l ow rate on the temporary l ow meter equals the value determined using the pump head and the pump curve, the l ow rate is validated, and the ei ciency is validated by association.
If a power meter is installed on the motor driving the pump, the measured kilowatt (kW) value can be compared to the calculated
power consumed using the pumps l ow, head and ei ciency values as show in Equation 1, at the bottom of page. kW = .746 × Q × H × ρ 247,000 × ηP × ηM Equation 1 Where: Q = l ow rate in gpm H = pump head in ft ρ = l uid density lb/ft3 ηP = pump ei ciency ηM = motor ei ciency
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PUMP SYSTEM IMPROVEMENT
If the power into the motor as read on its power meter is the same as the calculated power consump-tion using Equaconsump-tion 1, the pump’s l ow, head and ei ciency values are validated.
If a power reading is not available for the motor, the motor’s power consumption can be calculated by measuring the current and voltage supplied to the pump’s motor, then using Equation 2. h e motor’s power factor can be read on its nameplate.
P3ϕMotor = √3 × V × I × Pf
1,000
Equation 2 Where:
P3ϕMotor = motor power in kW
V = voltage volts I = current amps Pf = motor power factor If the calculated value of motor power equals the pump’s power con-sumption, the pump l ow, head and ei ciency values are validated. Tank Levels and Pressures h e tanks and vessels make excel-lent piping system boundaries. h e energy at each tank can be deter-mined by using the elevation of the liquid level in the tank and pressure on the liquid surface.
From these values the energy consumed for the static head compo-nent can be easily calculated.
h e results can be cross-validated using installed pressure and level instrumentation.
h e liquid level can be checked with a sight glass or by manually measuring the liquid level in the tank. h e pressure in a closed vessel can be compared using the installed plant instrumentation, installed pressure gauges or a temporary pres-sure gauge.
Control Valves
In last month’s example, the dif-ferential pressure across the control valve was calculated by subtracting the sum of the head losses of the process elements from the pump head. h is approach is easy, but any errors made in the previous calcula-tions will compound and can greatly reduce the energy cost balance sheet’s accuracy.
Valve manufacturers dei ne the operation of control valves based on tests that are outlined in published industry standards. Manufacturers use the ANSI/ISA-75.01.01 Flow Equations for Sizing Control Valves to size control valves for piping systems. h e data used in valve sizing can also be used to calculate the dif erential pressure across the control valve.
Equation 3 shows the basic for-mula for valve sizing.
Cv = Q FP
√
P1 – P2 S Equation 3 Where: Cv = manufacturer-supplied valve coei cient Q = l ow rate in gpmFP = piping geometry factor
(unit-less)
P1 = absolute pressure measured at valve inlet in lb/in2
P2 = absolute pressure measured
at valve outlet in lb/in2
S = l uid specii c gravity (unit-less)
Rearranging the control valve sizing equation and solving for dif-ferential pressure results in Equa-tion 4.
dP = Q
2S
(CvFP)2
Equation 4 In the example system with a l ow rate through the level control valve of 2,500 gpm, the control valve posi-tion is 65 percent. According to the manufacturer’s data for the control valve, the Cv at this position is 391.
h e FP of .9996 was calculated
by the manufacturer and included in the valve data sheet. h e spe-cii c gravity of the process l uid was calculated at .993. h e l ow rate through the level control valve was measured at 2,500 gpm. Inserting the values into Equation 4 provides the dif erential pressure across the control valve.
Converting the control valve’s dif erential pressure of 40.6 pounds per square inch (psi) to feet of l uid results in a head loss of 94.3 ft. h is result for the control valve calcula-tion validates the number from last month’s calculations.
Process Equipment
h e dif erential pressure across the process equipment was calculated using the pressure drop data sup-plied by the manufacturer and the
dP = Q 2S (CvFP)2 = 2500 2× .993 (391 × .9996)2 = 40.6 psi
