In today's era of heightened energy consciousness, businesses are reevaluating their production equipment to identify opportunities for energy savings. One crucial aspect under consideration is the cost associated with compressed air. This article delves into the transformative journey of Rustoleum, a coatings manufacturer in Decatur, GA, as they sought to enhance their fluid transfer processes. The focus shifted from traditional Air Operated Diaphragm (AOD) pumps to more efficient alternatives, ultimately leading to substantial energy and maintenance cost reductions.
For fluid transfer needs, many industries employ Air Operated Diaphragm (AOD) pumps. A typical scenario involves a 2" AOD pump transferring 50 gallons per minute (GPM) of lightweight fluid at a discharge pressure between 40 to 50 psi, with an inlet air pressure of 70 psi. However, when dealing with viscous fluids and higher discharge pressure requirements, the AOD pump's performance parameters can vary significantly.
Rustoleum faced a unique challenge in transferring a viscous, high-particulate metallic coating with an AOD pump. The 3" AOD pump operated with an inlet air pressure of 120 psi and a discharge pressure of approximately 30 psi, resulting in a discharge flow of 40 GPM. Notably, the abrasive nature of the fluid prompted frequent maintenance, with the AOD pump requiring new wetted parts every 3 to 4 weeks, incurring repair costs of around $500 per service.
In a bid to mitigate both maintenance and energy costs, Pye-Barker Engineered Solutions recommended the Viking LS4124A 3" internal gear, positive displacement pump. The integration involved c-face mounting the pump to a speed reducer and driving the assembly with a Premium Efficiency 7.5hp 1750 rpm motor. To enhance durability, carbon graphite bushings were replaced with hardened iron bushings, and the pump transitioned from a mechanical seal to packing, considering the fluid's abrasive characteristics.
The Viking LS4124A pump surpassed expectations, achieving a transfer rate of 65 GPM while experiencing reduced parts replacement frequency. Notably, the transfer rate increased by nearly 30%, and power requirements decreased by 50% compared to the AOD pumps. Encouraged by this success, Rustoleum extended the transition to their West Virginia plant, replacing AOD pumps with Viking positive displacement pumps for the same sand-based, highly viscous fluid.
The Rustoleum case study underscores the pivotal role of advanced pump technologies in optimizing fluid transfer efficiency. The adoption of Viking positive displacement pumps not only addressed the maintenance challenges posed by AOD pumps but also significantly reduced energy consumption. As businesses strive for sustainability and cost-effectiveness, investing in innovative solutions becomes paramount.
Ready to revolutionize your fluid transfer processes? Discover the transformative power of Viking positive displacement pumps and embark on a journey towards enhanced efficiency, reduced maintenance costs, and sustainable operations. Reach out to Pye-Barker Engineered Solutions today to start your optimization journey.
