via the system , which can often mean pumps are controlled by the closing of valves to reduce or stop flow , or recirculate flow .
Although the flow of a pump may have stopped , its power consumption remains the same , and if stopped abruptly or ran against a closed valve there is the potential for damage to be incurred .
By utilising a variable speed drive it reduce energy usage by more than 50 %, with associated savings made in spare part usage and maintenance too .
PUMP SET UP & TYPE As pumps are controlled by the system they are installed in , there are certain telltale signs that equipment is not working as it should . It could sound excessively noisy , be vibrating heavily , or produce less flow than normal .
Having a pump operating at full speed only within a process - in particular cooling applications is worth investigating to see if the pump and process could operate at a variable rate .
Similarly if a pump is frequently operating with a relief valve open this is a sign that the pump set up can be optimized .
MAINTENANCE Frequent spare part usage can often be a sign that something is not quite right within a process . Sometimes it can be taken as a given , that Mechanical Seals , O Rings , Stators , Diaphragms or Peristaltic Pump hose failure are a cost of the process . By undertaking failure analysis with a trusted pump supplier insight can be obtained if the rate of failure is normal and is as expected .
Sometimes small changes may be required such as the changing of a packed gland seal to a mechanical seal to help recover any fluid lost which is not charged for . On other occasions it could be that the pump type needs altering .
If Pump cleaning is performed manually , automating it for cleaning via CIP , or changing to a low maintenance pump design can accelerate the speed in which colour , recipe or production changes are carried out reducing downtime .
Should a pump be operating for over 10 hours a day its energy efficiency rating should be checked as older motors are rated as IE1 which can be between 5-20 % less efficient than premium efficiency IE3 or IE4 motors .
Pump age can also play a part in improving results , where newer more efficient designs are available for applications . Often the greatest cost of ownership derive from maintaining and running the unit , so it often pays to upgrade should the unit be several years old .
SYSTEM CALIBRATION / SET UP Pumps are not intelligent by design . Their performance is typically controlled
PRESSURE REDUCING VALVES In systems where pressures are too high for the next stage of a process , pressure reducing valves can be used to reduce incoming pressure .
When these are used the energy within the liquid is dissipated and wasted within the valve . If pressure reducing valves are used frequently in plants operating 24 / 7 there are possibilities to recover this energy via a Pump as Turbine which recovers the energy as reducing the pressure .
If you are looking a ways to improve a process , minimize wastage , improve productivity or downtime , speak to North Ridge Pumps on 01773 302 660 , via Live Chat , or email sales @ northridgepumps . com to discuss your process and see how we can help .
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