Pumps and seals — The synergistic combination

Pumps and seals - The synergistic combination By Roy Szweda, Contributing Editor A strong contributory factor impacting the market for seals and sealing products

pumps

is that of the changes within

and

companion US$l9

the world

report to this publication,

pumps

industry.

According

to a

the world pumps market has reached

billion per annum. This article provides an overview and market forecast

for the sealing products serving this market. It looks at the world pump market

as it existed

as it moves

in the second

into

half of I999

the new millennium.

In

keeping

with other titles in the series, the Pumps

Profile

is replete

company

profiles

with

geographic

analysis,

and directory.

and how it closely relates to that of sealing products. One key aspect has been the growing of seal-less pumps

outside

specialist

and in the mainstream. ongoing

sealing

technology.

synergistic with all

the

interdependence barometer downturns

the

sectors

general

- in the world

with

commercial

or lesser extent

of these

of

products,

new

To a greater

in

is increasing

of existing

2004.

-

or

marketplace.

to slightly

below 4% in

represents

between

points

year

forecast

reviews

the

3% in 2000

growth.

major

In addition,

slowly from

GDP

In

in real terms.

will increase

This

US$102.7

Faced with choices

will be some 16.5% larger than

rates of growth

percentage

the

gives a good

progress

in 1999

annual

just under

the two sectors’

consequent

opportunities.

technology

interdependence

each iteration

that

the

developments

Therefore

mutual

of

of pumping

comparable

the 2004 market

applications

At the same time,

diversi~cation

is demanding

acceptance

above

Total

0.5

the expected

and

are

expected

1

rate of

to

be

billion.

its fourth

the markets, manufacturers

international quantitative

the

the

Pumps

technological of liquid

Profile

trends pumps

and on an

basis. It looks at all aspects, and qualitative,

both

of the market

for

on the marker,

correct

one

straightforward spectfyrng

sealing

gaskets

the

which the

medium the

makes choosing

application

being

application of

but is also resistant sealed

and

able

temperatures

to and

pressures. If the following the selection

factors

of a gasket

are always

applied

type,

successful

then

to

sealing can be achieved:

Pump market indicators This article overviews gaskets and related the pumping industry

the marketplace

products

industry.

fares is always

a good

it is instructive

companion

products

of the sealing

to look at one of the

in the

engineeering

products

International

Pump Industry

It follows

to 2004. discussions

by

indicator

and tomorrow’s

market.

Therefore

Western

in

The way that the pump

state of play of today’s products

for seals,

for applications

stable,

neatly

of sealing Europe

product

to

of &he

Prospects

on from

previous

markets

America

be

industrial

- Market

product

and North

type

EAT

rhe I+oj/e

found

for

as well as in

Sealing

Technology. This market

study

from US$13.9 billion

the world

that

spare parts)

the world

with

a real increase

inflation. market

The report will grow

0 1998

1999

2000

2001

2002

2003 , 2304

14240

14645

f572? ---7

pump

will have grown

billion in 1999 through

in 2000,

1.5% excluding that

predicts

(excluding

I

13500

13870

US$14.2 of about estimates

at an annual

average rate of more than 3%, to a total of nearly US$16.2

billion

by 2004

Sealing Technology No. 86

(see Figure

a

when

is not only capable

surfaces,

application

not

important

for a particular selected

the mating

withstand

for

task. It remains

that the material

to edition,

is a large choice of static sealing materials

available

fluid seal sales in the five-

period

There

1). In fact

0

l

the temperature

l

the pressure

l

the corrosive

of the media nature

synergistic

to be contained;

of the media to be contained;

industrial

sectors.

As the direction

of the application.

Nevertheless,

despite

sharing

base in terms of engineering Reputable correct

gasket

suppliers

specification

offer a trouble-shooting or complex With

technology, have little Each

on environmental

issues, most gasket based

the January

2001

gasket

manufacturers

outlets

spectrum

pumps

for liquids

of products.

A consequence

this is that a correspondingly sealing

products

is required.

capital

absorbing

for power

manufacturing pating

in the pumps

two

industry. are smalloffering particular

market.

are

pump

specific

been

prompted

motor

1 shows

with

by a combination

similar growth also evident

seals have reliability

in the process

and magnetic

market

pump

market

drive models

North

America,

conventional

pumps

finally Japan.

is

by region

of

major

of the key factors

engineering however,

figures.

The total yearly consumption

the past half-decade,

for

to reach double

markets. may well not be

according

in the single of engin-

products,

these two

which

increase

in

and this does not look set

figures for the next half-decade,

to market

analysts.

command

pump

Diaphragm

\

is dominated than

by gasket half the

industry

companies

the

world

followed

by

of the World

Profile market

and

analysis

in Figure 3.

competence

in

processes,

and

and development. in the pump

an

element

spare parts

technical

report

sector

products

such

oil seals and

next

US$300 technology, business that

the

is that

evolution

years,

million.

packings

the

nearly to

sector, demand is

so,

sector

a year

reach

still remain

Even

containing all-important

5%

So, despite

packings sector.

face seals, rotary

packing

by

interesting

gaskets

For

of

high-performance

as mechanical

compression

-

in the sector’s One

of

non-metallic

to grow

Group

& Seals’ - provided

marketplace.

few

including

from the Freedonia

materials.

the

These

and inspection.

seals market

regional

of

and overhaul field

as to the ongoing

product

forecast

repair

in the

Study Gaskets

pointers

competing

part support.

supply,

the pump-related

advanced

are seal-related.

of after-sales

support

in

the discharge

important

commissioning

A recent

amount

is expended

during

of which

form

insrailation,

A significant industry

of problems many

Pumps

the

pump

manufacturing

of contracts,

largest

and

To survive,

have up-front

of R&D

some

basis.

must

research

and

is technology-based

marketing,

‘US Industry

@

Rest

on a global

operates

include

\

the

The Pumps

downstream

5% \

leading Europe,

for 2000 is shown

the resolution

Other

terms,

is Western

Global operations The

design,

more

is

dent in rhe seals

the market

seal products

While the seals market

to readers of Sealing Technology. There between

is holding

for mechanical

eered seals has not seen a significant

companies,

and technologies

which

growth

a it is

for a few more years.

seals.

the

are

of seal-less pumps

to make a serious

In geographical

one

The

markets

the two following

that the impact

pump

This

two

graph.

track. From this presentation

not expected

mechanical

on

pumps

a single

evident,

considerations.

spare parts

more than US$5

the seals and

on

immediately

in to replace

with one or

both

information

and seals. This has no of

by of the

by 2004

the

machinery

However,

sector, canned

inclu-

followed

US$6 billion

between

of mechanical

pump

Figure market

there is also the undeni-

makers to

products,

worth

and

command

up of the aftercare, is already

similarities

and market-driven hand,

of some

prominent

each

billion,

and will approach

based

private

are many parallels to be drawn

activity most

which

their biggest

by rotary

(Figure 2).

are moving

These and other characteristics unfamiliar

doubt

pumps

which

which,

manufacturers,

products

mechanical

improvements.

5000

and

is made

market, billion

sector that seal-

and ‘other’ types. The balance

market

the

collec-

half of the market.

to make

US$1.6

diaphragm

The largest of these

in

to medium-sized

ding

contributed

partici-

subsidiaries

companies Most

worldwide

operations,

exceptions,

than

largest

of engineering

able fact that

oil and

they market

lines.

and acquisitions

world’s

On the other

of horse-

are more

mergers

the

financial

to large

or offshore

companies

are multinational

international

thousands

There

can

units for

applications

generation

gas installarions.

pumps

horsepower

leisure and hobby plant,

power

These

of

pumps,

which

is followed

types,

approximately

readers will be aware of the unprece-

manufacturers

of

wide range of fluid

range from small fractional domestic,

cover a

Although

for similar

types,

for more than

This

is also

If the world

by type, dominating

are beginning

reciprocating

may in some cases also

the latter

less pumps

in either centrifugal

to their main product

dented

So too, industrial

is

contribution.

pumps.

is divided

market

of pump.

will be centrifugal

companies’

displacement

supply

Regular

viable

alternatives.

broad

positive

generally

have had to

commercially

displacement manufacturers

market

market

pump

Note that it is in the centrifugal

other.

which

individual

the world

by one category

tively account

industry

each

expertise,

Most specialise

positive

offer

regulations

with

market,

pump

and fluid

of the pump

its own

in establishing

centrifugal

in

Technology).

tightening

high-performance,

or

to specify

sectors

has

reputations.

and

(as discussed

issue of Sealing

As a result of continually of this kind,

users want

solutions

many

total

dominated

a common

principles

or no connection

sector

essential

applications.

non-asbestos

develop

made,

service for non-standard

today’s emphasis

related

that the and will

can confirm

has been

of

one evolves, so too does that of the other.

and

a

the

of

advance

of

an important

Freedonia will

over

value

observes

expand

Sealing Technology

more

No.86

slowly than the gaskets and seals sector. Gains the

packings

by

the

area

are

continuing

performing

being

throttled

replacement

alternative

by

better-

of key applications.

the

compression

market,

the

by the rising use of seal-less This is because

compression

most

with

directly

functional

to be hurt

centrifugal

competition

compete face

packings

5000

pumps.

packings

mechanical

moulded

Like

packings

market has all the signs of continuing

Nevertheless,

10000

sealing systems - especially

shaft seals - in a number seals

in

back

seals.

0

also offer some

for compression

in certain settings, says Freedonia.

Commercial impact As noted

previously,

seal-less pumps the seal market. conventional packed

the commercialisation

is having

an adverse

glands

but

sealed liquid

end. The

transmitted

to

this

a

seals.

Cl Europe

6947

cl ROW

3133

shaft are

to form a completely

prime sealed

mover end

energy

via

is chosen,

external

of the magnetic

because

seal-less operation

safety - rotary

shaft seals are not required,

the pump

housing

magnetic

power

without

contact

transmission,

since and the

there

are easy to service,

minimised

by the

all

use of a small

number

components

and by the fact that worn

be replaced

without

of

parts can

the need for special

materials

life. They

guarantees

are robust;

contact with the medium

the

is protected

by an outer

casing of cast iron, allowing

it to withstand

internal

forces.

external

and

of powerful

permanent

magnets

transmission

forces,

even at high

Friction losses are reduced matched

materials

use powerful,

magnets

which

transmission thus permitting Probably

process.

high

temperatures.

practice

manufacturers’

leakage

from

using

be tolerated, hot,

suited

in chemical,

efficient

is of

applications

and

should

thing of the past if the seal-less pump

be a

option

from

is

1 m”/h,

industrial

applirefinery,

brewery,

This

Nikkiso which

widely

used

Mechanical

magnets

or been

which

the sealing shroud power is received

magnetic

seals, known

ring attached

can

range

wasteful

pressures

for their unique

afford processing

benefits over less sophisticated They

maintenance

metallic

designed

and maximum

but

has

to the impeller.

heads

has a canned

was originally

of the nuclear

of external

extend

seal

periods

unplanned

engineered

power environment, in general

to

reliability

shutdowns,

industry.

barrier

of fluid control

to defend

the middle

seal-less

approaches

and that

reliable

because

to leakage

than

packing.

responses, seals ground

between

of packings.

is that mechanical barrier

and their

that is superior to other

continue

more

plannedcostly

such as compression

In the spectrum

chief advantage

into

reduce

film-lubricated

sealing products,

design

plants many

sealing alternatives. life

and

provides a sealing solution

is the

requirements is now

system

dairy

to 400 bar.

pump,

glands

driveshaft

by an internal

and long life-span,

are rated

-100°C

example

conventional

packed

The

by a bank

The seal-less

a

The sealing spectrum

liquids.

from

centrifugal

without

drag.

shaft. Magnetic

differential

with

pump

into

is no need for a

is

internally

10 to 500 m and over a temperature

to 450°C

terms

to the impeller

petrochemical, nuclear,

its constant

simple

seals.

replaced

there

wherever

from

pump.

in

as a

pumping

centrifugal

service. These pumps

meet the zero-leakage

assess all the options.

seal-less

marine,

Another

be borne

seal with

pump

coupled

as no shaft penetrates

in Asia as

hazardous,

and biochemical

from vacuum

In as much

of the pumps,

no

applications.

to solve critical

force through

sealed pumps with

design

pass the motive

expensive

for

and

an ideal

recognised

seal-less

used

pharmaceutical,

at flowrates benefits

(known are

or

are well

the world.

offers

typically

corrosive

improved

noise

this range

increasingly

the body shaft

it can

a growing

around

mechanically

toxic,

motor

No.86

These

cannot

burn-out.

from

HMD

pumps

in the pumping

by seal failure

pumps).

make

problems.

mechanical

‘zero leakage’

called

motor

the

been

sophisticated

centrifugal

pumps ‘no-seal’

with

has

and cause a burn-out.

companies

low

for even the most arduous

are available

UK-based

containment,

compactness, problems

solution

pump

find a built-in

is misapplied

For example,

specific

caused

pumps

the output,

the pump:

avoids

pump

the motor

range of specialist

non-seal

Downtime

seal-type

cations

will, of course,

to thoroughly

of the magnets

If a typical

- or not. Much will depend

willingness

Sealing Technology

slipping

and secondary

alignment

to a

- especially

will protect

permanent

highly

governs

liquids with higher densities-will that

Primary

efficiencies,

In the last few years the mechanically

the pump

In addition,

of any risk of leakage

This opinion

torque

drive

power to the impeller,

fluids

option,

magnet

high delivery volumes.

absence

a more expensive

HMD’s

by the use of optimally

ensure

or corrosive

out through

guarantees

one of the most important

the complete expensive

use

high-quality

of the motor

high

The

for the bearings.

the pumps

in

coupled

of applications.

misapplying

factor

special

magnetically

are seen as fundamental

Since the magnetic

Seal-less

a long

housing

they

number

overload

tools.

They have a long service life, since the exclusive use of high-quality

today

growing

safety

with downtimes

are no expensive

At first,

were considered

anyone

by electro-

thus excluding

leaks. They

but

and ecological

is sealed hermetically

are driven

pumps

drive centrifugal

pumps include

on

2852

seals to replace.

Advantages

service

II Japan

Dynamic

magnets.

pumps

6357

without

used to seal the impeller

replaced by a static shroud

El N. America

on

is basically

pump,

or mechanical

seals normally

of

impact

The seal-less pump centrifugal

1

packings

The

seals create a

traditional

packing

alternatives,

eliminating

chemicals Mechanical their

in a more

manner.

Common

element

that

enviromnentally

packing

must

be

replaced

require training

and some maintenance

whereas

are available,

mechanical

without

attention.

seals

last

However,

solution

has a relatively

pumps

with conventional

having

to be repaired

installed

but they

drive

attention,

several

years is

seal-less

i.e. the

Although seals

the component

is more

packings,

than

the life-cycle

alternatives,

of the sealing

appropriate

period

significantly

less. This

of

seals are low-friction leak

cooling

last

new cost-effective is one

treatment

facilities

of

the

as phase

piece

of equipment

choosing

the

PSEG with

Over

seal

machines

with

the

utility

with

mechanical

evaluation utility

and

of

again

same

seal.

retrofitted

chose

seals yielded

The

seal, from

inch

that

Five

After

months

Chesterton’s

442 Split Seal plant

A 1997

(ROI)

report

to mechanical

net savings

of nearly

US$200,730. Conversely, process

it is for the

industries

have a measure example,

Ethyl

where

more

challenging

the seal-less

of superiority. Corporation’s

pumps

In the US, for Petroleum

are

face,

Under

these

conditions,

recommended (SWG).

metal

These

and

a filler outer

mandrels.

custom-designed

SWGs

flanged

compatible

pumped.

Flexitallic’s increasing

Application conventional

these

When

to choose

of

the

or

gaskets

pumps

the

industries’

of fluid seals have

operations

around

follow

customers,

the

A more

components

the

the strategic automotive and chemical

local

supply

is an important

of

part of

Seal manufacturers that

looking

are becoming

many

equipment

at total lifetime

Installing

shorter

but should

are now

costs before

they buy,

seals a little too often

factor in the sale of a pump. lifetime

seals seems less costly,

the equipment

fail between

the situation

Likewise,

is

seals more

required

loss of productive

the equipment

planned

can easily become

with lower-grade

downtime

consequent

increasingly

buyers

and reduction

with

operation in output,

the from

with all

that this entails.

between

to find a

the very expensive

seal, and the one which

but long-

will ‘just about

lower cost. At the same time, the

vendors

must

response

to the

provide

an

trend

effective

towards

the

market seal-less

option.

are for a

seals will tend

Pump Industry - Market

2004 and the Profile of the International Sealing Industry - Market

being

gaskets

For more information about both the Profileof the International

specifying

fluid

the

metal

are

in pumps.

state-of-the-art

centrifugal

are

metal winding

Kammprofile

of

their

etc.

from

of an increasingly

oil and gas industry

do’, at a much

a preformed

manufacturer

application

of

that process.

lasting

generally

of gaskets

-

It is the lot of the seal manufacturer

spiral-wound

of

with

cost

up with these changes is

dutifully

their

machinery

balance

loading.

graphite

closure.

it is imperative

stress which

(often

Often

elements

finding

across

periphery

by the

seal

- will both be

Major purchasers

maintenance,

to maintain

a

challenges

preoccupation

companies,

frequent

winding

the

to be

bolt

industries

Keeping

to expand

reversed.

types

by spirally

on

particular

major

applications

difference

seal

more

participants.

temperature

use

strip

winding

a

In

it would

to

the

the need to

overall

to the end-user

faced with

and

uneven

and

could be a deciding

by Flexitallic’s

and

protection.

with

lower

and the need to replace

the seal.

be said

recovery

variable

seals

prices in turn for higher

and

pump

aware

operating

rotation,

and

under

of

replacement the

seals.

flange

opt

seals and

consult

comply

have to pay the higher performance

housing fluid

at bearing will

and

manufacturers

only have a

and creep, a gasket is required

manufactured

users

of

for as

containing

pressure

a seal

PTFE)

in

is illustrated

has the flexibility

gasket

seals.

the conversion

flange

attempts

moves

it is also inescapable

a temperature

relaxation

the inadequate

manufacturers

For

configuration.

conventional

As

result,

can be

the user will probably

bearing

a

Canned

justification.

Gas seals and hermetic

or

of any

of operating

could

mechanical

fluctuations,

thorough

in the main

to mechanical

there

economic

pump

as they

- the trend is

a proper

seals

pumps.

drive applications

traditional

world,

price. Undeniably,

included

that

of

for the more

is

which

with maintenance

require

a riposte

applications,

d’werse nature.

of the

manufacturer

of the equipment

range

be

the

the

However,

be

way

where

machines

manufacturers,

all pumps

CCMUA

well

additional

to

staging

the the

all

return-on-investment that

procedures

covers

delivering

products

it capable

life, and

some

manufacturer

this is a vital

that many seals, or seal components, limited

as lacking

The

- the industry

consistent

good performance.

the main

period,

two

seals.

substations

indicated

so

Company

so

frt

split-seal

converting

year-end

to

the

later,

when

performed

decided

to make

seen

had

for

of seal-less

Reliable gauge of status and progress

of replacement

industry,

at a competitive

growth

and magnetic

ownership.

service.

products

sales

manufacturing,

long as possible,

gallons per day. test

product

to fit one

Seal

a

Additional

of the importance

sector

sense

schedule

with a 5.875

eight-month

Chesterton CCMUA

Split

of a

(using

sector.

it makes

pumping

a mechanical

pump

20 million

an

the

A.W. Chesterton

for a main raw-sewage shaft moving

a

wastewater

decided

Chesterron

Massachusetts-based

because

for longevity

Process

two. After evaluating

and substations,

In the fluid sealing

consideration,

for

the main plant and six main

plant

parts.

motor

were recovered

sealing

and

the consumer

for the utility.

and

sales

responsible

to find

largest

one

for fluid

original

In the sealing

with only one part of the utility at

as phase

market

maintaining

on the US East Coast,

a time, designating

stations

(PSEG)

sealing solution

CCMUA

PSEG worked

Group

seal).

costs to install the pump

which

the Pennsylvania-based

that

pump

mechanical

Utilities

Jersey,

twice

sealed centrifugal

both

is shown

Municipal

no

cost for the seal-

was approximately

after-market

in New

Engineering

substations

less

supplies.

County

with

Systems

fewer

consume

then

Ethyl said that

Vital seals after-market sector The

less

require

and

(CCMUA)

partnered

be

mechanical

of how well this works

Camden

Authority

often

that consume

longer,

water or ancillary

over an

can

is because

shutdowns,

An example by

time,

devices

less,

unplanned

installation

since

slow down

may well replace

as

cost, or the total cost to

the operator

energy,

such

So it

magnetic

after only one year of maintenance-free

cost of mechanical

the

and

and installation

project

lifetime of the pump.

pump,

single

seals were

Engineering

the purchase

standard

and

every four months.

has been required.

mechanically

to

caustic

point,

mechanical

it

of its

The

high freezing

maintenance

less pump

implies that this period is extended

when

rate

hydroxide.

a Dynaflow

less options

infinite,

unloading

sound

lifetime prediction

purposes

the

of sodium

not always an exact science. The threat from seal-

be for all practical

had some problems

boost

deliveries

frequently.

packings

to

to run

is a disposable

Process-quality

Division

wanted

supplies.

seals also allow plant operators

plants

Additives

the risk that hazardous

will leach into groundwater

Prospects to Fluid

Prospects to 2004, contact:

Amanda Arthur, Elsevier Advanced Technology, PO Box 150, Kidlington, Oxford OX5 1AS, UK. Tel: +44 1865 843181, Fax: +44 1865 843971, Email:

to

a.arthurQelsevier.co.uk,

to

http://www.worldpumps.com

Web:

A

Y_Y

Sealing Technology No. 86