The Turbomachinery and Pump Symposia (TPS; www.tps.tamu.edu) is taking place Dec. 11–14 at the George R. Brown Convention Center in Houston. This event, organized by the Turbomachinery Laboratory, part of the Texas A&M Engineering Experiment Station (College Station, Tex.; www.tees.tamu.edu), consists of a technical conference program and an exhibition hall, both featuring experts from around the globe who specialize in rotating equipment. For the first time, TPS is co-located with Insulation Expo USA (IEX), an event dedicated to commercial and industrial insulation. This year, TPS has over 300 exhibiting companies who will showcase a wide variety of products and services aimed at users of pumps, compressors and other types of rotating machinery. The following is a small selection of the TPS exhibitors’ offerings.
Gear pumps with flexibility for custom configurations
The 4900 Series of gear pumps (photo) are hydraulically balanced and well-suited for demanding chemical-processing applications. The pump’s performance characteristics include flowrates up to 300 gal/min, viscosities from 0.5 to 1,500,0000 cP, discharge pressures up to 2,000 psi and temperatures as high as 850°F. The pumps’ unique design contains no castings, but rather all machined components allow adaptability for custom configurations and material selections. Additionally, the pumps are available in either a horizontal or a vertical configuration. Booth 1116 — Northern Pump, a division of McNally Industries, LLC, Grantsburg, Wis.
Comprehensive maintenance for all types of rotating equipment
This company’s maintenance services for rotating equipment incorporate both large-scale projects and the manufacture of specific components, as well as the provision of fully integrated services ranging from the design stage through final onsite installation. These services are aimed at turbines, compressors, pumps, generators and large motors — with full refurbishments of rotor blades and coils available, supported by in-house manufacturing capabilities. Also available among the maintenance offerings are anti-fouling air-spray coatings that provide protection against corrosion for compressor rotors and other similar components. The company also provides 3-D printing capabilities to create high-performance components, such as turbine blades. 3-D printing presents expedited production compared to traditional casting, offering reduced lead times. Booth 2023 — Sulzer Ltd., Winterthur, Switzerland
These flowmeters are equipped with intrinsically safe sensors
The Coriolis RCT1000 line of mass flowmeters (photo) was recently enhanced with the addition of an explosion-proof transmitter with intrinsically safe sensors. The hazardous-location certification opens up an array of new applications for RCT1000 flowmeters, including chemical and petrochemical processing, oil exploration and refining, and a wide variety of industrial processing applications in potentially hazardous environments. The RCT1000 mass flowmeter identifies flowrate by directly measuring fluid mass over a wide range of temperatures with a high degree of accuracy. For fluids consisting of two liquids or a liquid with suspended solids, this system can derive the concentration and mass of each fluid based on the density measurement. The unobstructed, open-flow design makes it suitable for a variety of fluids, such as slurries and other viscous, nonconductive fluids. Booth 1203 — Badger Meter, Inc., Milwaukee, Wis.
An integral-gear design boosts these air compressors’ efficiency
AeroBlock (photo) is a standardized air compressor that is designed with integral-gear (IG) compression technology, and its standardized design ensures consistency without the need for specialized parts, which enables faster turnaround and support. AeroBlock compressors achieve flowrates up to 54,000 m 3 /h and can handle pressures up to 13 bars. The AeroBlock is specifically engineered for use in the industrial gas and hydrocarbon processing sectors. The multi-speed capability of IG technology allows each compression stage to run at the optimal speed, giving the best efficiency possible. According to the manufacturer, AeroBlock air compressors achieve 1.5–2% greater efficiency when compared to previous models. Booth 2725 — Atlas Copco Gas and Process, Cologne, Germany
Locate and classify leaks quickly with this handheld device
The Sonochek ultrasonic testing device (photo) localizes specific leaks on high-pressure pipes and evaluates total loss volume. Its broad bandwidth of 20 to 100 kHz allows leaks on compressed-gas and air pipes to be tracked, even from a distance. The Sonocheck device comes with two apps: Sonolevel and Sonoleak. Sonolevel is a universal leak-detection tool that facilitates basic condition-monitoring tasks for bearings. Users can also check condensate separator status and monitor electric control cabinets for spark production. The Sonoleak app is used for precise localization of leaks, and can also rapidly determine the exact leakage loss volume. Corrective actions can be identified quickly, as the leak is classified into five different categories. All ultrasound signals are directly converted into digital signals, and the Sonochek device is fitted with various sensor attachments for both airborne and structure-borne transfer of ultrasound. Booth 2042 — Prüftechnik Condition Monitoring GmbH, Ismaning, Germany
An all-inclusive solution for lubrication management
The LUBExpert acoustic lubrication solution’s (photo) intelligent algorithms guide technologists and operators during and after re-greasing tasks, resulting in optimal lubrication parameters on all assets. LUBExpert monitors each stroke of grease and its effect on bearing friction and temperature, and generates a status report both before and after re-greasing, enabling robust trending of friction levels and grease consumption for each asset. The LUBExpert package includes the Ultranalysis Suite (UAS) software, which powers data management. With UAS, users can design specific lubrication routes and set intervals based on either a calendar or equipment condition. UAS stores data on the capacity of each bearing, preventing over-lubrication. Booth 2735 — Ludeca, Inc., Doral, Fla.
High-efficiency variable-speed drive for compressors and pumps
The VECO-Drive (photo) is an electric superimposing gear that combines a mechanical planetary gear with frequency-controlled servo motors. The electrical superimposing gear is said to be the most efficient way to make speed variable. The servo motors used to drive the planetary gear only need a small part of the rated power, resulting in an overall component efficiency of more than 97%, according to the manufacturer. The VECO-Drive is installed between a constant-speed motor and a variable-speed compressor or pump. Since additional power is supplied to the drivetrain, a smaller main motor can be used, saving capital expenditures. Moreover, the servo motor can be used as a starter to protect the electric grid from high inrush currents. The VECO-Drive is designed as a modular system and thus offers individual specifications for different application types, classes of explosion protection and speed levels. Advanced functions like the integrated PLC-based output controller, user interfaces, condition monitoring and simplified maintenance are part of the scope of supply, and remote access and remote diagnosis are available as needed. Booth 2145 — Voith Turbo, Inc., York, Pa.
Test hydrogenation processes at realistic conditions in this dedicated pilot facility
This company has added to its hydrogenation portfolio with the launch of a new pilot plant in Schopfheim, Germany, called the Hydrogenation Test Center. The new facility enables testing and realistic simulation of industrial hydrogenation processes, from catalyst handling to the actual reaction to catalyst separation. The new test center provides operators of hydrogenation units the ability to determine scalable product and process parameters to facilitate efficient commissioning. Typically, these types of trial runs and experiments are only run at laboratory scale, but the new test center allows for more robust tests to occur at more realistic production conditions at pilot scale. The pilot plant features a primary hydrogenation reactor made of Alloy C22 with a volume of 60 L that can be operated at temperatures up to 250 C and pressures up to 100 bars. Additional 3-L complementary reactors are also available on site. Booth 2616 — Ekato Rühr- und Mischtechnik GmbH, Schopfheim, Germany
New tool for pulsation analysis in piping systems
This company has launched its Pulsation Frequency Analysis (PFA) module as an addition to its waterhammer-analysis software AFS Impulse. The PFA module extends the Impulse software so that engineers can more readily analyze and model pulsation in piping systems to help them quickly evaluate possible solutions. Pulsation is a common problem in systems if the frequencies it excites are at or near the system’s acoustic resonant frequencies — often leading to system weakening and frequent maintenance outages. The PFA module is compliant with the API 674 standard, which defines the allowable pulsation limits for positive displacement pumps. PFA enables users to predict and understand resonant frequencies in order to avoid their undesirable effects in piping systems and asses system compliance with API standards. Booth 2435 — Applied Flow Technology (AFT), Colorado Springs, Colo.
Diamond-based coatings increase service life of high-wear surfaces
This company’s patented ultrananocrystalline diamond (UNCD) coatings for seals, bearings and other high-wear surfaces in rotating equipment have demonstrated the ability to greatly expand equipment performance capabilities in many field applications. UNCD, a form of nanocrystalline diamond, captures many of properties of natural diamond in a scalable thin-film technology that enables diamond to be integrated into a wide range of products. UNCD coatings are manufactured using patented chemical vapor deposition processes. According to the company, UNCD coatings are not diamond-like carbon films, but rather phase-pure crystalline materials consisting of ultra-small diamond grains ranging from 2-5 nm up to 1 micron in size, depending on the variety of UNCD. When incorporated onto rotating-machinery components, these coatings can enhance parts’ resistance to dry running conditions and decrease the occurrence of catastrophic failures. Booth 1225 — Advanced Diamond Technologies, Inc. (ADT), Romeoville, Ill.
A liquid-ring compressor with conical porting
Maxima-C bare-shaft double-acting liquid-ring compressors are suitable for compressing contaminated and corrosive process gases because of their ability to handle saturated gas mixtures and large amounts of liquid carried over from the process. Designed for heavy-duty applications, with low operating noise levels and low maintenance, the compressors’ discharge pressures range from 5 to 90 psig. The Maxima-C design features conical porting instead of the flat-plate porting offered on similar models. The cones are attached to the end housing of the pump and protrude into the impeller on both sides. Air enters the impeller in a radial direction versus axially when compared to the flat plate design. The primary benefit of this design is its ability to handle more seal liquid or liquid carryover through the suction compared to the flat plate design with less effect on power consumption and better performance when handling saturated inlet gas, according to the manufacturer. The Maxima-C features a 20-blade shrouded rotor and heavy-duty cones and bearings. Packed gland sealing is standard with optional mechanical seals available. Other features include removable bearing brackets, multiple inlet/discharge port configurations and a casing partition allowing for different operating pressures at each inlet port. Booth 2812 — Dekker Vacuum Technologies, Inc., Michigan City, Ind.
Dual-functioning product can be mixed as a repair mortar or grout
MasterEmaco T 5000 repair mortar and grout is resistant to a wide range of industrial chemicals. MasterEmaco T5000 is a multi-functional solution used to repair damaged concrete or to grout smaller equipment that will experience varying levels of chemical exposure. Depending on the project requirements, the material can be mixed to create either a thick repair mortar or a flowable grout. The product is a 100% solids resin system for solvent-free and nearly odor-free application. MasterEmaco T5000 has been evaluated against 240 chemicals, and its performance for each is documented in the product line’s online Chemical Resistance Guide, available at www.masteremaco-t5000.com. The seven-day strength reaches 11,040 psi as a repair mortar, and 10,000 psi as an ancillary grout. The versatility of using one product for both repair and ancillary grout applications provides contractors and facility owners with jobsite flexibility and reduced inventory requirements, says the manufacturer. Booth 2724 — BASF Corp., Shakopee, Minn.
www.master-builders-solutions.basf.us
An online content repository for mechanical-seal best practices
The FSA’s recently launched website feature, KnowledgeBase (www.fsaknowledgebase.org), provides content and informational videos as a service for manufacturers and users of mechanical seals. This digital knowledge base provides easy navigation to key information to educate and inform users of best practices for safe, reliable and cost-effective operation of mechanical seals, including guidelines for proper specification, applications and maintenance, as well as equipment design and materials of construction. Although the KnowledgeBase is currently focused on mechanical seals, the FSA plans to expand the feature and load content into three additional subject repositories covering gaskets, pump and valve packings and expansion joints. Booth 1200 — Fluid Sealing Association (FSA), Wayne, Pa.
Non-contact gas bearings improve rotor balancing
Bently Bearings are pressurized air bearings that provide non-contact support for rotors during balancing operations. Specifically, the device produces a consistent signal that is exactly the same for each revolution, allowing for finer resolution during balancing operations, says the company. This helps to eliminate both damage to the rotor from hard rollers, and the mess of oil-film bearings in vacuum environments. Unit loading of air bearings has been demonstrated at over 400 psi, using 600-psi input pressure. With normal shop pressure of 100 psi, the air bearings will carry 60 psi unit loading. Booth 2710 — New Way Air Bearings, Ashton, Pa.
Simulate complex granule phenomena with this new software
Granuleworks is a simulation software for granulated materials that is based on discrete element analysis (DEM). Granuleworks can analyze various complex granule behaviors, including mixing, conveying, filling and compaction, as well as enable simulation of the motion of powder particles in fluids. The major fields of application for Granuleworks are the food, medical goods, chemicals, transportation and electric materials sectors. The software is built with an intuitive user interface that facilitates simulation from pre-processing steps through post-processing. The software’s 3-D view window features ultra-fast, high-quality rendering for large-scale simulations with millions of particles. Multiple windows can be compared side-by-side for easy handling. Both Linux and Windows are supported. — Prometech Software, Inc., Tokyo
“Smart” couplings now available with this IIoT service
The Smart Coupling product line features this company’s IIoT Smart Tag Solution, which brings increased levels of connectivity by providing on-demand information to assist with streamlining and shortening new product installation, service maintenance, troubleshooting and changeover times throughout the product’s lifecycle. Users have immediate access to accurate model identification information and up-to-date inventory from the closest distributors (with pricing and lead-time estimates). Also available is access to specific model number information for equipment installed onsite locally, with the ability to send alerts to users on product service activities and performance feedback for installed equipment. The IIoT Smart Tag Solution interface is available on smartphones, tablets and PCs. Booth 1407 — Rexnord Industries, LLC, Milwaukee, Wisc.
Updated design software with new compressor-casing feature
This company has released Version 8.6 of its Agile Engineering Design System software, an integrated suite of computer-aided engineering (CAE) and computer-aided manufacturing (CAM) programs that is specialized for turbomachinery. This integrated system enables users to optimize designs based on the impact to cost, machining time and performance. A new feature in Version 8.6 is a recirculating casing treatment (RCT) for compressor range extension that is integrated throughout the entire design process from preliminary design through 3D geometry, grid generation and flow solving. The newest version of the CAM module, MAX-PAC focuses on making complex 5-axis programming simple and efficient. Features include new virtual milling functionality that simulates material removal. Other enhanced features are more options for roughing, new plunge milling strategies for harder materials and new options for high-quality point and flank milled blades. Booth 2127 — Concepts NREC, White River Junction, Vt.
This machinery-protection system provides early indication of fault development
The AMS 6500 ATG System is a standalone machinery protection solution that also allows users to cost-effectively introduce prediction monitoring of critical assets from the same system. With four reconfigurable cards, the AMS 6500 ATG can be set up in the field for a wide range of protection measurements, including embedded prediction capabilities, such as impacting or peak-to-peak data. With the impact data, users can monitor the start-up and coast down of critical turbomachinery for safe operation and receive the earliest indications of developing faults in gearboxes and bearings. The AMS 6500 ATG provides API 670 protection on many types of critical equipment, including steam turbine generators, gas turbines, boiler feed pumps, pipeline turbo compressors, chemical industry compressors, turbo exhausters, blowers and boosters. Booth 2601 — Emerson Reliability Solutions, Round Rock, Tex.