Pump SGS ession Descriptions by KF3fUk



The 28th International Pump Users Symposium is sponsored by the Turbomachinery Laboratory of the
Texas Engineering Experiment Station, The Texas A&M University System. The Advisory Committee for
this symposium is composed of engineers from various user and manufacturing corporations throughout
the U.S. and abroad. The presenters of Lectures, Tutorials, Case Studies, and the Discussion Leaders are
leaders from the fluid-handling-equipment community. The Advisory Committee is greatly indebted to
these individuals for their participation and outstanding contributions.

Advisory Committee

Dr. Dara W. Childs, Chairman             Texas A&M University                      College Station, TX
Mr. Ronald B. Adams                      Sulzer Pumps                              Brookshire, TX
Mr. Henri V. Azibert                     A.W. Chesterton Company                   Groveland, MA
Mr. Simon Bradshaw                       ITT Goulds Pumps                          Seneca Falls, NY
Mr. Morgan M. Bruck                      Hydraulic, Measurement, and               Dayton, OH
                                          Inspection Consulting, LLC
Mr. Gordon S. Buck                       John Crane Inc.                           Baton Rouge, LA
Mr. Ronald J. Carlson                    Flint Hills Resources                     Corpus Christi, TX
Mr. David E. Earl                        Conoco Phillips                           Anchorage, AK
Mr. Matthew A. Gaydon                    Bechtel Power Corp.                       Gettysburg, PA
Mr. Kerry F. Gunn                        LyondellBasell                            Houston, TX
Mr. Robert F. Heyl                       Chevron                                   Houston, TX
Mr. Michael Huebner                      Flowserve Corporation                     Deer Park, TX
Mr. Jacek M. Jarosz                      Flint Hills Resources                     Houston, TX
Mr. Michael W. Johnson                   GenOn Energy                              Houston, TX
Mr. John P. Joseph II                    Rotating Equipment Systems, LLC           Friendswood, TX
Mr. William R. Litton                    Magellan Midstream Partners LP            Tulsa, OK
Mr. William D. Marscher                  Mechanical Solutions, Inc.                Whippany, NJ
Mr. Todd Monroe                          LyondellBasell                            El Lago, TX
Mr. Mike L. Moore                        Colfax Corporation                        Ontario, Canada
Dr. Gerald L. Morrison                   Texas A&M University                      College Station, TX
Mr. Bruno Schiavello                     Flowserve Corporation                     Phillipsburg, NJ
Mr. Eberhard Schlucker                   University Erlangen-Nuremberg             Erlangen, Germany
Mr. Joseph A. Silvaggio, Jr.             Siemens Demag Delaval                     Hamilton, NJ
                                          Turbomachinery, Inc.
Mr. Leslie Thilagan                      KBR Energy and Chemicals                  Houston, TX
Mr. Eric Vanhie                          EagleBurgmann                             Houston, TX
Mr. Bruce Weber                          Champion                                  Houston, TX
Mr. Daniel W. Wood                       DuPont                                    Wilmington, DE
Mr. Chris Zielewski                      ExxonMobil Chemical                       Baton Rouge, LA

A Short Course is a full-day training session presented concurrently with other sessions on the first day of
the symposium.

Short Course P1/T1: Vibration Problems and Solutions in Pumps & Turbomachinery
Monday, September 24, 2012           8:30 – 5:00            Level Three, Room 351D
William D. Marscher , Paul A. Boyadjis, Maki M. Onari (Mechanical Solutions, Inc.,Whippany, NJ)

Vibration evaluation of rotating machinery will be covered on a practical basis, with focus on
centrifugal pumps, axial and centrifugal compressors, and steam and gas turbines. Analysis concepts,
test procedures, diagnostic methods, and troubleshooting approaches will be presented, all in the
context of machinery internal construction and physical functioning of the machine. Representative
Case Histories will be provided for a variety of equipment and problems.

Ten Rules in Turbomachinery Operation for “Good Vibrations”:
    1. Match Design Point to System Head & Flow Requirements
    2. For Pumps, Require NPSHA Above NPSHR, with Margin
    3. Use a Long Straight Piping Run to the Inlet
    4. Careful When & How You Throttle
    5. Avoid H-Q Slopes Being Similar, Machine vs. System
    6. Minimize Nozzle Loads & Use Exp Joint Tie Rods
    7. Avoid Structural Natural Frequencies & Rotor Criticals
    8. Minimize Load Cycling, if Practical
    9. Select Materials Based on Corrosion, Galling, Fatigue & Erosion Resistance
    10. You Get What You Spec & Pay For

   - There’s More to Turbomachinery Vibrations than Expected
   - Keys to Success: Knowledge, Experience, the Right Tools
   - Good Rules-of-Thumb Exist for Troubleshooting and Diagnosis
   - Good Vibration Methods & Instrumentation Are Getting Better

Short Course P2/T2: The Utilization of Computational Fluid Dynamics in Turbomachinery Design and
Monday, September 24, 2012              8:30 – 5:00           Level Three, Room 360C

Instructors: Dr. Edward M. Bennett and Travis A Jonas (Mechanical Solutions Incorporated); Vishwas
Iyengar (Prospect Flow Solutions, Houston, TX); Grant O. Musgrove and Andrew H. Lerche (Southwest
Research Institute, San Antonio, TX); James Hardin (Elliot Company, Jeanette, PA)

Computational Fluid Dynamics (CFD) has emerged as a leading tool for the design and analysis of
incompressible and compressible turbomachinery. CFD is now routinely applied to solve problems of
performance, forced response, cavitation and multiphase flows, heat transfer and rotordynamics. As
with all computational tools, CFD must be used with care to ensure accurate and reliable results.

This course will serve as an introduction to the use of CFD using as examples a variety of problems in
incompressible and compressible turbomachinery. It will cover the basics of CFD, and then proceed
directly to a number of case studies where CFD has been applied to resolve challenging fluid dynamic,
thermodynamic, and forced response issues that routinely arise in turbomachinery, for selected
situations involving pumps, compressors, and turbines of various designs and services. The course will
demonstrate the effectiveness of this tool to resolve complex phenomena when used with caution as
well as a full understanding of its capabilities and limitations.

The course will cover several key parts:

AM Session – Incompressible Turbomachinery Flow:
   1. Fundamental Concepts
   2. Pump Case Study One: Cavitating Pump
   3. Pump Case Study Two: Axial Pump Stage
   4. Hydraulic Turbine Case Study Three: Francis Turbine Stage

PM Session – Compressible Turbomachinery Flow:
   1. Pitfalls of CFD
   2. Performance Predictions
   3. Role of CFD in RCFA
   4. Fluid Structure Interaction (FSI)
   5. Rotordynamics
   6. Conjugate Heat Transfer

Short Course P3: Pumps 101
Monday, September 24, 2012                 8:30 – 5:00           Level Three, Room 370D

John P. Joseph II (Rotating Equipment System Technical Association, Friendswood, TX) and Daniel Wood
(DuPont, Wilmington, DE)

This course is aimed at engineers and technical professionals who need a broad-based introduction to
basic pump selection, application and operation. This course starts with the basics and builds to provide
a full understanding of centrifugal, rotary and reciprocating pumps. The course will include the following
topics: centrifugal, rotary and reciprocating pump similarities/differences; centrifugal, rotary and
reciprocating pump configurations; nine fundamental principles for reliable pump operation; developing
pump specifications; understanding pump curves; developing system curves; choosing a type of pump
for a specific application. The course will answer the question “What are the things I need to worry
about when selecting, specifying and operating pumps?” At the completion of the course, the attendees
will hold a strong understanding of basic concepts. This knowledge will act as a springboard to further
growth understanding of more complex pump concepts. An emphasis is placed on providing practical
information with minimal theory and thus, comprehension of the information presented requires little
to no mathematical skills in hydraulic or mechanical design. This is NOT a pump design and/or
maintenance class.

Topics Covered:
   - Pump Types and Construction
         Classification and Nomenclature
            Centrifugal Pump Types
            Special Designs
            Special Effect
            Positive Displacement Pump Types
           Basic Pump Design
             Centrifugal Pumps
             Rotary Positive Displacement Pumps
             Recip Positive Displacement Pumps
    -   Comparison of Centrifugal, Rotary and Reciprocating Pumps
    -   Materials of Construction
    -   Centrifugal Pump Performance
         Performance Curves
         Specific Speed (NS)
         Suction Specific Speed (NSS)
         Family of Curves
         Suction Conditions and Limitations on Suction Performance
         System Curves
         Affinity Laws
         Parallel and Series Operation
    -   System Design - The Nine Principles You Must Follow for a Reliable Pump Installation
    -   Services and Selection of Pumps
         System Analysis
         Selecting the Right Type of Pump for the Application
         Selecting the Right Pump Features for the Application
         Procuring the Pump
    -   Installation, Operation and Maintenance

Short Course P4: Fundamentals of Centrifugal Pump and System Interaction
Monday, September 24, 2012           8:30 – 5:00            Level Three, Room 370F

Michael Volk (Volk & Associates, Inc., Oakland, CA)

This short course is offered for engineers and technicians who are responsible for system design, pump
selection, operation, maintenance, or repair. The primary objective is to examine the relationship
between centrifugal pumps and the systems in which they operate. The course shows how the system
affects pump operation, energy consumption, and the relative amount of pump maintenance problems.
This course follows up on many of the topics introduced in a formerly offered short course, “Basic Pump
Hydraulics with a Minimum of Mathematics,” though that course is not a prerequisite.

   - Pump performance curves
   - Head-capacity, horsepower, and NPSHR curves
   - Effects of operation at other than BEP
   - System head curves
   - All-static system
   - Dynamic system
   - Changes in system head curve
   - Branch-line pumping systems
   - Viscous liquids
   - Effects on pump performance curves
    -    Effects on system head curve
    -    Multiple pump operation
    -    Parallel operation
    -    Series operation
    -    Oversizing pumps
    -    Variable speed pumping – how it works, benefits
    -    Software solutions - benefits of software for system analysis, case studies using software,
         summary of available software

Short Course P5: Pump Cavitation Physics, Prediction, Control, and Troubleshooting
Monday, September 24, 2012            8:30 – 5:00              Level Three, Room 371D

Bruno Schiavello (Flowserve Pump Division, Phillipsburg, NJ) and Frank C. Visser (Flowserve Pump
Division, Etten-Leur, Netherlands)

   - Session 1: Cavitation Physics
   - Session 2: Cavitation Prediction
        Emphasis will be on the most influencing parameters rather than on actual mathematical
        formulas, which can help both the Engineer and the User to assess the relative importance of
        the key aspects for: a) correct pump selection and specification and b) successful field
        troubleshooting failure analysis. Moreover, the value and potential use of CFFD will be
   - Session 3: Cavitation Control *NPSHR3%, NPSHA, Life Expectancy
            o Pump designer role
            o Highlights on critical evaluation of design target, basic design criteria, and system
                designer role
            o Highlights on acceptable critical marginal pump operations and pump abuse
            o Pump selection and specification
   - Session 4: Cavitation Failure Analysis (Methodology)
            o Cavitation modes recognition
            o Diagnostic approach
            o Solution strategy

Short Course P6: Ever-Tightening Environmental Regulations – Meet Them or Shut Down
Monday, September 24, 2012             8:30 – 5:00           Level Three, Room 371F

Henri Azibert (A.W. Chesterton Company, Groveland, MA), Ron Carlson (Flint Hills Resources, Corpus
Christi, TX), Rich Davis and Brian Hasha (Flexitallic L.P., Deer Park, TX), Peter Koegl (Hermetic Pumps,
Houston, TX)


    I.       Introduction by Ron Carlson
             a. Gasket Systems – Rich Davis with training device
               b. Brief coverage of EP A regulations and end user experience – Ron Carlson
               c. Mechanical Seals – Henri Azibert
               d. Sealless Pump Technology – Peter Koegl
    II.        Miscellaneous Information From an End User – Ron Carlson
               a. First attempt cleaning
               b. Honing gasket surfaces
               c. Coating or spraying shafts
    III.       Some coverage of EPA regulations – Ron Carlson
               a. Leak Detection And Repair (LDAR)
               b. HON and VOC
               c. Links to EPA web site for additional information
    IV.        Gasket Systems – Rich Davis
               a. Gaskets Function and Design
               b. Gasket Types
               c. Installation and Assembly
    V.         Lunch Break
    VI.        Mechanical Seals – Henri Azibert
               a. Elements of mechanical seals
               b. Liquid Lubricated
                         i. Leak rates
                        ii. Forces
                       iii. Power consumption
                       iv. Limitations
               c. Non Contacting Seals
                         i. Definition
                        ii. Face technology
               d. How to meet emission regulations
                         i. Seal operating environment
                        ii. Single seals
                       iii. Dual seals
               e. Conclusion
    VII.       Sealless pumps – Peter Koegl
               a. Types of Sealless Pumps
                         i. Magnetic Drive Pumps
                        ii. Canned Motor Pumps
               b. Comparison of the features and capabilities
               c. Examples of installations

Short Course P7: Mechanical Seals 101
Monday, September 24, 2012            8:30 – 5:00                Level Three, Room 372D

Michael Huebner (Flowserve Corporation, Deer Park, TX), Henri Azibert (A.W. Chesterton, Groveland,
MA), Eric Boyce (John Crane, Webster, TX), Eric Vanhie (EagleBurgmann, Houston, TX)

Mechanical seals are a critical component in the reliability of any centrifugal pump and pumping system.
Understanding the fundamentals of these components is critical to ensuring their proper maintenance
and operation. This short course will examine the basics of mechanical seals and their interaction with
pumps and support systems, Students will learn about the function and considerations for seal piping
plans and support systems. The course will also cover installation procedures and failure analysis.
Finally, the students will learn about tools which will allow them to evaluate the life cycle costs of
sealing alternatives. The presenters will have examples of various seal models and failed components for
examination and discussions.

Short Course P8: Rolling Element Bearings
Monday, September 24, 2012             8:30 – 5:00                Level Three, Room 372F

Brian Dahmer (SKF USA Inc., Lansdale, PA), Simon Bradshaw (ITT Goulds Pumps, Seneca Falls, NY), Bob
Eisenmann (BP), Terry Roehm (Marathon Oil), Morg Bruck (Hydraulic, Measurement, and Inspection
Consulting, LLC, Dayton, OH)

Bearings are a critical component in a pump or turbo machine. The machine cannot perform well unless
the bearings are accomplishing their tasks of supporting and positioning the shaft, allowing shaft and
housing to rotate relative to each other with minimal friction while transferring loads from the shaft to
the housing. Bearings are complex items themselves. Internal components in bearings are subjected to
very high pressures while separating rolling components on a lubricant film that is thinner than one ten
thousandth of an inch. In addition to the mechanical complexity inherent in today's rolling element
bearings, there are many different types and features that must be understood to maximize
performance of a bearing system.

The purpose of this course is to provide an overview of the purpose of rolling element bearings, the
different types of bearings, bearing components and their function, standardized dimensions plans and
bearing materials. Typical arrangements, loading conditions and selection of bearing size are also
covered. Design of adjoining components (shafts and housings) will be discussed. Lubrication methods
and lubricant selection are included as are friction and heat generation. Handling, storage and
installation are included as well. Lastly, common failure modes and their causes will be covered.

Completion of this short course should provide an overall understanding of the complexity of rolling
element bearings and the elements of the bearing system. Bearings themselves are dependent on
adjoining components, seals and lubrication in order to function well so understanding the
interdependence and interaction is very important. Understanding bearing selection, even for those
individuals that are not designing bearings systems, is important since an understanding of the different
bearing types and life calculations allow the individual to predict the effects of changing loading, speed,
bearing type of lubricant on the bearing.

This short course is intended for anyone working with bearings. This would include machinery designers,
field service personnel, assembly supervisors, consultants, reliability engineers, troubleshooters and
anyone else with a need to understand bearings more completely.

A Lecture is a presentation of a technical paper detailing cutting-edge, emerging technology. Two
lectures are presented consecutively in one 90-minute time slot.

Lecture P1: Operational Problems in Pumping Shear Thinning Slurry Resolved Using Laminar Flow
Fitting Loss Model
Tuesday, September 25, 2012           10:30 AM               Level Three, Room 370D

Daniel Wood (DuPont, Wilmington, DE) and Trey Walters (Applied Flow Technology, Colorado Springs,

A case history is presented pertaining to five pumping systems that operated satisfactorily until a new
production requirement was imposed. A new slurry product initially developed at lab scale was
introduced into the production plant for an initial trial run. Problems began to surface immediately on
three out of five batch process pumping systems when the slurry could not be pumped through the
plant at contract rate. Additionally, significant "heels" (unwanted fluid levels) were left in some of the
suction vessels that were unable to be pumped out, resulting in considerable yield losses. This
manufacturing problem had not been anticipated by the team, and without quick resolution, a loss of
customer confidence and a significant delay in the new product would have resulted.

Investigation and analysis of the system revealed two major problem areas in pumping non-settling
slurries in laminar regimes:

       Initial prediction of head losses through suction piping fittings was flawed using traditional
        hydraulic loss methods. The original calculations for NPSHA values for the pumps predicted
        adequate NPSH margin. The fluid was non-Newtonian and was operating in the laminar regime.
        Upon further investigation, a weakness was revealed in predictions of fitting losses for laminar
        flow through the pipe fittings. An improved model for predicting losses through pipe fittings was
        identified and implemented. The improved model matched operational data much better and
        provided the critical insight needed to resolve the operational problems and get the facility
       Piping arrangements that allow for features such as clean-out ports (e.g., branch flow tees) can
        be counterproductive to unrestricted flow of the process liquid in systems with non-settling
        slurries operating in laminar regimes. Tees, elbows, diameter changes, and other fittings can
        introduce significant head losses in the pumping system.

The authors present an improved method for analyzing fitting losses in pumping systems when dealing
with non-settling slurries operating in the laminar regime. In addition, design considerations are
presented to minimize the impact that piping has on the pumping system when handling non-settling
slurries operating in the laminar regime.

Lecture P2: If You Install a Pump Subsea, Leave Nothing to Chance
Tuesday, September 25, 2012             10:30 AM               Level Three, Room 370D
Instructors: Pierre-Jean Bibet and Bernard Quoix (TOTAL, Paris, France)

In 2011, for the first time, Hybrid Multiphase Pumps have been deployed on the seafloor. This was
Offshore Angola, at 800m Water Depth, to ensure the full field development of Pazflor Deep Sea Project
by pumping the viscous oils of the Miocene fields. Through the example of these Pazflor subsea pumps,
this paper invites the reader to discover, step by step, the thorough acceptance tests program that was
put in place to mitigate as much as possible the risks before installation. This paper relates how, after 15
months of Acceptance tests, the eight Hybrid Pumps were declared Ready for Deployment.

Lecture P3: New Advances in Pulse Width Modulated (PWM) Slip Power Recovery Drive for Pumps
Tuesday, September 25, 2012          2:00 PM              Level Three, Room 370D

Stephan Bondy (TMEIC, Houston, TX)

Since its invention by Nikola Tesla in 1888, the alternating-current (AC) motor has been a critical driver
for the industrial age. One of his original three patents was the wound rotor induction motor (WRIM).
Later, Westinghouse refined the design of the wound rotor motor to permit control of the speedtorque
characteristics of the machine. This paper discusses a new advancement in Pulse Width Modulated slip
power recovery drives (PWM-SPR) application for pumps. By using sophisticated adjustable speed drive
control, a significant amount of slip power can be fed back to the utility line, hence resulting in energy
savings. Also, application examples are discussed to enhance understanding.

Lecture P4: Mechanical Seals for High-Speed Boiler Feed Pumps in Ultra-Pure Water
Tuesday, September 25, 2012            2:00 PM               Level Three, Room 370D

Eric Vanhie (EagleBurgmann, Houston, TX) and Benjamin Weiss (Eagleburgmann, Wolfratshausen,

Since 2007, the hot-filament Chemical Vapor Deposition (CVD) technology for crystalline diamond thin-
film coatings has found its way into the mechanical seal market to combat the problems of dry running,
corrosion and abrasion. This new technology has proved successful in hundreds of pumping applications
in a wide range of services and duties. The reliability and lifetime of mechanical seals are improved by
using diamond-coated faces. One such application involved the sealing of large boiler feed and steam
generator pumps in power plants, which operate under high pressure, RPM, and temperature
conditions. Consequently, the mechanical seal faces are highly loaded in a fluid with less than ideal
lubricating qualities. These applications are technologically challenging for mechanical seal
manufacturers not only from a tribological perspective but also from a corrosion viewpoint when the
feed water has a low electrical conductivity or is free of impurities. This paper discusses a new seal-face
treatment using hot-filament CVD manufacturing technology tested in a lab for 16,000 hours and
currently used in feed pump operations in several power stations in the USA and Europe.

A Tutorial is a mini short course/workshop. It is a teaching process.
Tutorial P2: Advancements in Mechanical Sealing – API 682 Fourth Edition
Tuesday, September 25, 2012          8:45 AM                 Level Three, Room 370F

Michael Huebner (Flowserve Corporation, Deer Park, TX), Gordon Buck (John Crane, Inc., Baton Rouge,
LA), Henri Azibert (A.W. Chesterton Co., Groveland, MA)

API 682 continues to be the most influential standard for mechanical seal seals for centrifugal and rotary
pumps in the world. To keep up to date with the latest technology, the Fourth Edition has been
prepared and is currently in draft form. This presentation will provide an overview of some of the
significant changes in this revision and explain how this will impact both seal OEMs and end users.

Tutorial P3: A Guide to Gasketing Principles and Best Practices
Tuesday, September 25, 2012             2:00 PM                 Level Three, Room 370F

Mike Shorts (Triangle Fluid Controls Ltd., Belleville, ON) and Keith Guenther (Teadit, Pasadena, CA)

Leakage from static joints has been found to be a major contributor of emissions in many plants. With
the collaboration from the world’s leading gasket manufacturers, the Gasket Division of the Fluid Sealing
Association has created a training presentation that will assist all personnel dealing with modern
gasketing applications and issues. What may appear to be a simple and easy-to-install component
actually requires knowledge and understanding of its working principles and characteristics. This tutorial
will start with basic gasketing concepts and then proceed into details regarding installation & assembly.
It will also address equipment and fastener considerations, material selection, and common uses.
Finally, field failure analysis techniques will be explained so that errors in selection or installation
procedures can be corrected

Tutorial P4: Witness Testing of API 610 Centrifugal Pumps and API 611 Steam Turbines
Wednesday, September 26, 2012           8:30 AM               Level Three, Room 370D

Nirmal “Nick” Ganatra (FMC Technologies, Inc, Houston, TX) and Rajanikant C. Patel (Bechtel Oil, Gas &
Chemicals, Inc., Houston, TX)

The tutorial outlines the basic concepts and offers some tips on witness testing of API 610 centrifugal
pumps and API 611 steam turbines. The section on API 610 pump testing discusses performance, NPSH
and mechanical run tests of API 610 centrifugal pumps that are often specified with witness testing.
Various parameters that are measured during testing and the related instrumentation are introduced.
This section references related paragraphs and tables from ANSI/API Standard 610 (2010). The section
on API 611 steam turbine testing covers the mechanical run test and cites the related paragraphs of API
Standard 611 (2008). The same section also recommends a few additional tests that could be performed
on general purpose steam turbines, if feasible and applicable.

Tutorial P5: An End-User’s Guide to Centrifugal Pump Rotordynamics
Wednesday, September 26, 2012             8:30 AM                   Level Three, Room 370F

William D. Marscher (Mechanical Solutions, Inc., Whippany, NJ)

Rotordynamics will be presented emphasizing practical issues, focusing on pumps but also with
application to other turbomachinery such as compressors and turbines. Basic concepts key to analysis
(like Lomakin Effect, cross-coupling, and rotordynamic instability) will be discussed in a manner that
non-specialists can appreciate. Test procedures to determine rotor critical speeds and damping will be
presented as well as an outline of effective analytical techniques. Case histories will be used to illustrate
how the principles and procedures are applied.

Tutorial P6: CO2 Capture and Pumping
Wednesday, September 26, 2012        2:00 PM                        Level Three, Room 370D

Ron Adams (Sulzer Pumps, Brookshire, TX)

Tutorial on CO2 capture, transportation and injection for enhanced oil recovery or sequestration.
Capture includes methods for capturing CO2 from stack gases as well as economics of capture and
sequestration. Transportation covers when to consider compression or pumping and how the industry
has predicted dense phase supercritical pump performance in the past. Past experiences are shared on
subcritical (cold) and warm supercritical CO2 pumping, seal systems, materials, etc., dating from 1982.

Tutorial P7: Breaking the Cycle of Pump Repairs
Tuesday, September 25, 2012            2:00 PM                      Level Three, Room 382A

Heinz P. Bloch (Process Machinery Consulting, Westminster, CO)

Of the numerous process centrifugal pumps undergoing repair right this very minute, an estimated 90%
have failed randomly before. Some pumps ran just fine until the very first time we fixed them and were
never quite the same since. That begs answers to a few interesting questions: Could it be that we don’t
really know why so many of these pumps are failing? Could it be that we just don’t give pumps the
attention they deserve? Is it because everybody’s priorities are elsewhere?

The co-authors of this fact-filled tutorial point to design and selection factors whose importance was
either downplayed or overlooked. They show illustrations of component configurations that represent
inherent failure risks unless a number of operational and maintenance-related parameters are near-
perfect (an unrealistic expectation). The tutorial describes practical, tangible solutions in great detail and
steers clear of the usual consultant-conceived generalities.

Rather than presenting a theoretical treatise, this tutorial is a highly practical guide – you will be surprised
at the clarity and candor with which its author-presenters make their points. They call for and describe in
detail the common-sense engineering evaluation of certain improvement opportunities they have seen
implemented at absolute best-performing pump user companies world-wide. The presenters speak from
decades of experience and have no hidden agenda. Far from simply talking about the generalized
consequences of “business as usual” attitudes, they explain proven steps to improve pump life.

Improvement is both possible and valuable. Its cost-effectiveness can be quantified without much
difficulty. The key is to talk “management speak,” which includes “monetizing” the repairs, quantifying the
process losses, and doing B-over-C (benefit-to-cost) and life cycle analyses. Even more important are the
specific details that many pump users have never heard about; the co-presenters will bring them to your

Tutorial P8: Rolling Element Bearing Maintenance to Ensure Maximum Life
Wednesday, September 26, 2012          10:30 AM              Level Three, Room 370F

Brian P. Dahmer (SKF USA Inc., Lansdale, PA)

Rolling element bearing reliability is key to pump reliability. Without the ability for the impeller shaft to
rotate accurately and smoothly, a centrifugal pump cannot perform its desired function. Today’s
bearings are marvels of engineering and manufacturing. While many will complain that bearings are very
costly today, however when compared to bearing prices from a century ago (adjusted for the value of
money), today’s bearing prices are quite inexpensive. This is especially true when the precision level of
the bearing is looked at. Today’s angular contact ball bearings and deep groove ball bearings typically
used in centrifugal pumps have dimensional and running accuracy tolerances that are measured in ten
thousandths of an inch (a few microns) and raceway surface finish tolerances measured in millionths of
an inch (less than 1 micron). The materials used in today’s bearings are also much cleaner and stronger
than bearings from decades ago. So, today’s rolling element bearings are highly engineered precision
pieces of machinery capable of operating in demanding conditions for long periods of time. However,
bearings can only function reliably when the entire rotating system and adjoining components are
operating as designed.

The bearings that support the impeller shaft are complex machine components whose service life is
directly affected by:

·    Contamination (both particulate and water)
·    Lubrication method and lubricant type
·    Mounting and dismounting techniques
·    Selection of components
·    Control of inactive bearing rolling elements
·    Proper housing support and alignment

In addition, there are major risks to bearings from unexpected loading conditions as well as exposure to
vibration while idle. The effects of these conditions and how to avoid the risks need to be considered in
order to maximize service life.

Lastly, condition monitoring is an excellent way to maintain awareness of the health of bearings.
However, even the best condition monitoring tools and techniques are of little value if not implemented
and interpreted correctly.
A Discussion Group is a forum to address problems attendees bring to the floor and to find solutions to
those problems. Suggested Topics listed are suggestions only; actual topics discussed will be determined
by each session’s attendees.

Discussion Group P1/T1: Couplings and Alignment
Presented Twice
Tuesday, September 25, 2012           10:30 AM                  Level Three, Room 381C
Wednesday, September 26, 2012         2:00 PM                   Level Three, Room 371D

Discussion Leaders:
Thomas Davidson, Coordinator (Linde LLC, LaPorte, TX)
Terry Roehm (Marathon Oil Company, Houston, TX)
Morgan M. Bruck (Hydraulic, Measurement, and Inspection Consulting, LLC, Dayton, OH)
Michael Johnson (GenOn, Houston, TX)
Chris Rackman (John Crane Flexibox, Houston, TX)

Suggested Topics:
    Coupling guard design
    Shaft alignment and tolerances
    Balancing methods
    Coupling selection and specifications
    Shaft alignment methods
    Thermal growth considerations
    Application of optical alignment
    Hub/shaft fits and keys
    Coupling types and applications
    Startup problems
    7th Edition recommendations
    Allowable nozzle loads
    Warmup piping procedures
    Case deflection, temperature, and pressure
    Piping alignment
    Pipestrain

Discussion Group P2/T2: Monitoring Vibration and Other Critical Machine Conditions
Presented Twice
Tuesday, September 25, 2012          8:45 AM                 Level Three, Room 372D
Wednesday, September 26, 2012        10:30 AM                Level Three, Room 371A

Discussion Leaders:
William D. Marscher, Coordinator (Mechanical Solutions, Inc., Whippany, NJ)
Ron Adams, Coordinator (Sulzer Pumps, Brookshire, TX)
Mike Pepper, Coordinator (ExxonMobil, Houston, TX)
Steve Locke, Coordinator (DuPont, Old Hickory, TN)
Thomas Kaiser (Sulzer Pumps Inc., Brookshire, TX)
Paul Boyadjis (Mechanical Solutions, Inc., Whippany, NJ)
Al Miller (Flowserve Corporation, Taneytown, MD)
Jack Claxton (Patterson Pump Company, Toccoa, GA)
Maki Onari (Mechanical Solutions, Inc., Whippany, NJ)
Simon Bradshaw (ITT Goulds Pumps, Seneca Falls, NY)

Suggested Topics:
    Effectiveness of condition monitoring on unspared equipment
    Value of, or ROI of, condition-based monitoring
    ODS and integration with condition-based monitoring
    Vertical pump monitoring
    Below ground
    Hydraulic induced vibration: structural, system, rotor
    Vertical pump vibration standards
    Measurement and character of unsteady cavitation conditions
    Standard locations for vibration measurement on horizontal pumps
    Wireless devices: radio noise, effectiveness, experiences
    Vibration spectrum for 3-5% GVF in centrifugal pumps
    Vertical turbine pump structural resonance analysis
    Module pump installations, i.e., experience with nongrouted baseplates
    Vibration test methods and use
    Finite element analysis and use
    Condition monitoring methods
    Troubleshooting methods and fix options
    Hydraulic and system issues
    Mechanical installation issues
    Seals and bearings – how they affect vibration
    Rotordynamics

Discussion Group P4/T4: Gears
Wednesday, September 26, 2012             2:00 PM           Level Three, Room 371F

Discussion Leaders:
Cliff Cook (CVC Engineering, Houston, TX)
Lisa Ford, Coordinator (Lufkin Industries, Pollok, TX)
Greg Elliott (Lufkin Industries, Pollok, TX)
Marc Hagn (Enterprise Products, Seymour, IN)

Suggested Topics:
    New gear applications
    Power loss and oil flow considerations
    Rotordynamics
    Bearings for gear drives
    Installation questions
    Metallurgy/heat treat methods

Discussion Group P5/T5: Lubrication
Wednesday, September 26, 2012             10:30 AM          Level Three, Room 371F
Discussion Leaders:
Charlie Rutan (Stress Engineering Services, Inc., Houston, TX)
Leslie Thilagan (Bechtel Corporation, Houston, TX)
Kerry Gunn (LyondellBasell, Houston, TX)

Suggested Topics:
    Types of oils used
           o Mineral (A & B)
           o Synthetic
           o EP Oils
    Testing
           o Frequency
           o Types of Test (Internal Lab and Outside Lab)
    System Filtration (Microns?)
    Oil Mist
           o System design
           o Dry Sump
           o Wet Sump
    Greases
           o Type
           o Frequency
           o Grease mixing and compatibility
    Rolling Element Bearings
           o Failure cause identification
           o L10 life (Theory versus reality, Bearing versus system)

Discussion Group P6: Centrifugal Pump Operation, Maintenance, and Reliability
Presented Twice
Tuesday, September 25, 2012           2:00 PM              Level Three, Room 381A
Wednesday, September 26, 2012         2:00 PM              Level Three, Room 372F

Discussion Leaders:
Jacek Jarosz, Coordinator (Flint Hills Resources, Houston, TX)
Kerry Gunn, Coordinator (LyondellBasell, Houston, TX)
Dale Atwell (Celanese Corporation, Florence, KY)
Watson Tomlinson (Flowserve Corporation, Mount Holly, NC)
Ralph Borchard (LyondellBasell, Houston, TX)
Luis Gonzalez (Flint Hills Resources, Pine Bend Refinery, Rosemount, MN)
William McCullough (Flint Hills Resources, Pine Bend Refinery, Rosemount, MN)

Suggested Topics:
    Pump/system improvements for energy savings and optimization
    Seal-less versus sealed pump reliability, canned motor pumps versus mag drive pump reliability
    Pump predictive/preventive maintenance program elements
    Measures of effectiveness of preventive and predictive programs for pumps
    Roles of operations and maintenance/reliability in improvements and data collection
      Reliability experience with liquid versus non contacting gas seals applications
      Maintenance philosophy for pumps
      Spare parts – OEM versus non-OEM
      Repairs – OEM versus non-OEM service facilities
      Pump foundation, alignment and pipe strain influence of reliability
      Impact of corporate purchasing alliances on pump reliability
           o Repair facilities alliances
           o New equipment purchasing alliances
      Repair techniques and material improvements
      Portable and on-line monitoring – impact on reliability
      Wireless monitoring – impact on reliability and risk of failure
      Mean time between failure – how do we measure, and how do we use the metric?
      Optimization of thrust bearings configuration
      Lubrication system impact on reliability – oil mist versus flood, oil selection

Discussion Group P7: Mechanical Seals
Tuesday, September 25, 2012           10:30 AM                Level Three, Room 381A

Discussion Leaders:
Mike Huebner, Coordinator (Flowserve Corporation, Deer Park, TX)
Henri Azibert, Coordinator (A.W. Chesterson Company, Groveland, MA)
Eric Vanhie (EagleBurgmann, Houston, TX)
Shifeng Wu (A.W. Chesterson Company, Groveland, MA)

Suggested Topics:
    Electronic seal monitoring
    When and where to apply noncontacting double gas seal technology
    When and where to use dry running backup seals
    Mean time between failure – how to evaluate and compare
    Mechanical seals for multiphase applications
    Materials – i.e. compatibility, application, and life cycle with regard to face combinations, o-
       rings, packing, etc.
    Conventional tandem and double seals for emission control; system configurations, buffer fluids,
    Split seals
    High/low temperature applications
    Evaluating applications for sealed versus sealless pumps
    Slurries and other solid laden processes
    API 682
    Dealing with emissions regulations at county, state, or federal level

Discussion Group P8: Vertical Pump Problems and Solutions
Wednesday, September 26, 2012         10:30 AM                Level Three, Room 372D

Discussion Leaders
Eric Vanhie, Coordinator (EagleBurgmann, Houston, TX)
Bob Davis (Sulzer Pumps, Brookshire, TX)
Suggested Topics:
    Petrochemical industries
    Installation
    NPSH
    Materials
    Bearings
    Maintenance
    Vibration
    Lubrication
    Paper industries
    Power industries
    Tolerances
    Nozzle loads

Discussion Group P9: Sealless Pumps
Wednesday, September 26, 2012            10:30 AM                 Level Three, Room 372F

Discussion Leaders:
Ron Carlson, Coordinator (Flint Hills Resources, Corpus Christi, TX)
Dan Wood (Dupont, Wilmington, DE)
Jim Lobach (Teikoku/Chempump, Warminster, PA)
Dennis Fegan (Powerdyne Consultants, Houston, TX)

Suggested Topics:
    Types of sealless pumps & application limitations such as HP, pressure, temperature, solids, etc.
    Applications where sealless pumps have been successfully applied, and where they have failed
    Environmental performance in VOC or HON services.
    Any new developments to improve reliability or extend where they can be applied?

Discussion Group P10: Pipeline Application
Tuesday, September 25, 2012            8:45 AM                    Level Three, Room 381C

Discussion Leaders:
Bill Litton, Coordinator (Magellan Midstream Partners LP, Tulsa, OK)
Bruce Weber, Coordinator (Champion, Houston, TX)
Morg Bruck (Hydraulic, Measurement, and Inspection Consulting, LLC, Dayton, OH)
Ralph Dickau (Enbridge Pipelines, Edmonton, Canada)
George Maddox (Best Pumpworks, Tyler, TX)
Mike Nigro (Weir Services, Deer Park, TX)

Suggested Topics:
    Operation
           o Single
           o Series
           o Batch products
           o Parallel
      Maintenance
          o Mechanical seals
          o Bearings
          o Pigging
          o Vibration
      Hydraulic rerates
          o Destaging
          o Volute chipping
          o Volute inserts
          o Impeller underfilling
      Equipment monitoring
          o Types of monitoring
          o Data collected and stored
          o Cost of monitoring
          o Benefits of monitoring

Discussion Group P11: Energy Savings Through Facility Organization
Tuesday, September 25, 2012           2:00 PM                 Level Three, Room 381C

Discussion Leaders:
Joe Silvaggio, Coordinator (Siemens Demag Delaval Turbomachinery, Inc., Trenton, NJ)
Chris Zielewski, Coordinator (ExxonMobil Chemical, Baton Rouge, LA)

Suggested Topics:
    Operating the pump at the best efficiency point
    Pump operation with variable speed drives
    Trimming impellers to meet actual demand requirements
    Changing impellers for the pump application
    Optimizing the pump for the application
    Other hardware modifications of enhancing efficiency

Discussion Group P12: Improving Mean Time Between Pump Failures
Wednesday, September 26, 2012       8:30 AM              Level Three, Room 372D

Discussion Leaders:
John P. Joseph II, Coordinator (Rotating Equipment Systems, LLC, Friendswood, TX)
Bill Litton, Coordinator (Magellan Midstream Partners LP, Tulsa, OK)
Mike Smith (Flowserve Corporation, Irving, TX)
Morg Bruck (Hydraulic, Measurement, and Inspection Consulting, LLC, Dayton, OH)

Suggested Topics:
    Mechanical/Metallurgical design requirements for pump components
    Design and installation of pump baseplates
    Proper hydraulic fit of pumps
    Mechanical alignment targets/procedures
    Pump repair criteria
A Case Study is a short presentation describing the successful implementation of established technology
to solve a real-world problem.

Case Study Pump Session 1
Thursday, September 27, 2012            8:30 AM                 Level Three, Room 370D
   - Case Study P1: Uncommon, Very Effective Solution to PD Pump Pulsation & Vibration Problem
        Instructor: Eugene “Buddy” Broerman (Southwest Research Institute, San Antonio, TX)
   - Case Study P3: Power Savings on Recycle Applications
        Instructors: Mike Wisnoski (John Crane Inc., Cedar Rapids, IA) and Jeremy MacClure (Archer
        Daniels Midland Company, Cedar Rapids, IA)
   - Case Study P4: Modification of BB1 Pump Vibration Characteristics to Meet ISO 13709 2 nd
        Edition (API 610 11th) Limits
        Instructor: Simon Bradshaw (ITT Goulds Pumps, Seneca Falls, NY)
   - Case Study P8: Hydraulic Evaluation of an Off-Shore Pumping Station
        Instructor: Augusto Garcia-Hernandez (Southwest Research Institute, San Antonio, TX)

Case Study Pump Session 2
Thursday, September 27, 2012             10:30 AM                 Level Three, Room 370D
   - Case Study P2: Pump Piping System – Insufficient Dampeners
        Instructors: Eugene “Buddy” Broerman III and Sarah Simons (Southwest Research Institute, San
        Antonio, TX)
   - Case Study P5: Solving Super-Synchronous Vibration on a Double Suction Pump
        Instructors: William D. Marscher and Maki M. Onari (Mechanical Solutions, Inc., Whippany, NJ);
        Kris Olasin (Motiva Enterprises, Convent, LA)
   - Case Study P6: The Effect of Foundation Piers on the Natural Frequencies of a Vertically
        Mounted Sewage Pump in Resonance with Vane Pass Excitations
        Instructor: Paul A. Boyadjis (Mechanical Solutions, Inc., Whippany, NJ)
   - Case Study P7: Diagnosing and Correcting a Damaging Below-Ground Column Natural
        Frequency in a Vertical Pump Using Field Testing and FEA
        Instructors: Paul A. Boyadjis and Maki M. Onari (Mechanical Solutions, Inc., Whippany, NJ)

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