26/07/2013

The Hidden Technology Inside Pumps

Pumps may be familiar features of the workplace but what is less obvious is the fact that there are now many newly enhanced components that are improving performance within pump systems. These upgraded components - such as bearings, seals and lubricants - are meeting the pressing need to enhance efficiency and performance, says Phil Burge, Country Communication Manager, SKF.

Industrial and process pumps represent a significant financial investment for any business, particularly when it comes to energy consumption. Although modern pumps are inherently reliable, energy still accounts for at least 45% of the cost of ownership, and this is compounded by the fact that energy efficiency will decline over time due to factors such as cavitation and scaling. Then there are the maintenance issues: once installed many pumps are often largely forgotten until a problem occurs, and this adds still further to the cost of operation.

However, there are many ways in which manufacturing and process companies can improve the return on investment in pumps, leading to greater energy efficiency, better reliability and reduced maintenance. This can be achieved through the use of appropriate condition monitoring techniques, possible bearing replacement and upgrade, correct choice of seals and the use of the latest lubricants and lubrication systems.

A common challenge faced by engineers is the need to increase plant productivity while maintaining efficiency and performance. Higher throughput, however, requires greater rotational speeds, which in turn leads to higher temperatures, greater noise and vibration. The potential results include more frequent pump bearing failures, and costly downtime to repair often production-critical equipment.

To meet this challenge, and embrace the many potential solutions that are available, it may ultimately be more profitable to adopt integrated pump solutions with the help of an experienced engineering partner. These solutions vary with the needs and goals of each particular facility, but generally involve some combination of self-aligning and/or low-friction bearings, automatic lubrication systems, and maintenance and reliability services. By applying integrated pump solutions, customers can avoid the expense of replacing underperforming pumps and enjoy a range of benefits, including reduced vibration levels, lower operating temperatures, and increased reliability.

For example, by using SKF Explorer class bearings, lubricant consumption, as well as vibration and noise levels are all reduced, and when re-lubrication intervals are extended, maintenance and running costs are minimised. This is significant, because industrial pumps are typically hard to access and inadequate lubrication is a common cause of premature bearing failure, with this being the cause of more than one third of premature bearing failures. This can be avoided by installing fully automatic lubrication systems that enable maximum bearing service life and reduced operating costs to be achieved. Another option is to install pumps equipped with sealed, greased-for-life bearings that are considered to be maintenance-free, increasing meantime before failure (MTBF) and reducing total operating costs. When it comes to bearing failures, we estimate that 80% are caused by contamination, lubrication or mounting issues, and when bearings fail or require premature replacement, the result is reduced uptime, performance and service life. So, the best possible bearing specification and installation is key to improving efficiency.

An integrated pump solution will also defend people as well as profitability. Pumping systems can often be responsible for the movement of hazardous materials such as flammable hydrocarbons, toxic chemicals and thermally reactive chemicals, and any leakage of such material could represent a serious risk for workers and the environment. By helping you to keep pace with safety and environmental legislation, an integrated pump solution will provide a strong line of defence against such risks.

There are many roads that lead to pump efficiency, but the most direct route can often be to take an organised approach by investing in an integrated solution. By following a clear action plan and a scheduled condition monitoring and maintenance regime, you can run your pumps at the maximum level of efficiency.

Phil Burge, Communication Manager, SKF (U.K.) Limited

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