Historically our clients have been very diligent about installing monitoring solutions for their mission critical pumps. Due to the cost of installing the system and the cost of ongoing maintenance of the system, condition monitoring solutions for all pumps on site has been typically unrealistic.
Manual monitoring of the remaining pumps or a policy of ‘run until breakdown’ is normal which in light of today’s technology can prove to be MORE expensive and unnecessary.
Older monitoring systems meant wiring the sensors into the control center; it was expensive, time consuming and created a lot of infrastructure to maintain.
It meant a limited roll out of electronic condition monitoring to pumps with either a high risk of maintenance issues or a high impact when a maintenance issue does occur. For example – pumps that have repeat failures, pumps without spares or pumps where failure could cause an environmental incident.
With the advances of wireless technology the same monitoring systems can be installed without the time or expense of maintaining a complicated infrastructure. It has now become affordable to install a higher quality monitoring system across more of your pumping process system.
These three monitoring applications can help a plant implement predictive maintenance systems which can reduce maintenance costs, unexpected failures, repair and overhaul time – and at the same time increase uptime by up to 30% and increase MTBF.
Affordable Monitoring Application #1: Cavitation
While many cases of cavitation occur when a pump is operated outside of their design specifications, there are still times when a pump operating within its specifications can still experience cavitation.
A simple discharge pressure monitoring system (consisting of vibration monitoring and discharge pressure) can give your central monitoring system an alert when a pump is likely ‘pre-cavitation.’ Depending on the frequency of manual rounds this might mean the prevention of damage and downtime compared to discovering cavitation in progress.
For high-head multi-stage pumps – the risk of damage with even brief periods of cavitation means that pressure differential across the pump should be continuously monitored.
Affordable Monitoring Application #2: Vibration
Vibration monitoring systems can give you indicators on running condition as well as faults and failures. Vibration transmitters can give you a series of vibration frequencies which can in turn be used to diagnose the cause of the vibrations in a given pump.
Affordable Monitoring Application #3: Pump Seal Monitoring
For pumps that have auxiliary seal flush system, API 682 recommends moving from switches to continuous level management.
With recent advances in technology, rather than having to wire the monitoring system into the network it can be installed wirelessly and then connected to the central monitoring system.
I’ll admit it may take some retrofitting of technology to get the seal flush reservoirs installed so they can be remotely monitored. But continuous monitoring will give far more lead time to address maintenance issues compared to intermittent manual maintenance inspections of pump seals.
If it is time to increase the reliability of your pumping systems then the team here at Pye-Barker can help you select and install pump monitoring systems for your plant. Drop us a line at firstname.lastname@example.org or call 404-363-6000 for help with all your pumping system needs.
ARO is launching a new controller with remote operating capabilities. The new ARO Controller delivers on the promise of touch-and-walk-away automation with remote operating capabilities that increase the reliability, productivity and safety of fluid management.
“At ARO we take pride in solving our customers’ most complex fluid handling challenges with straightforward, yet smart solutions that keep their businesses moving,” said Nelson Wesley, global product leader for diaphragm pumps.
This new controller creates a fully automated multi-pump system
The new ARO Controller works seamlessly with ARO EXP Electronic Interface pumps to create a fully automated multi-pump system for batching, container and tank filling and chemical injection systems in a wide variety of applications. The controller can also be integrated with many existing ARO EXP pumps when an electronic interface package is added.
“The remote operating capabilities of the new ARO Controller help manufacturers increase reliability, productivity and safety,” Wesley said.
The multi-pump controller can be programmed with remote triggers customized to the application. The controller responds to those triggers and performs auto-shutdowns when necessary and sends data and service alerts to the operator. The operator is then positioned to make intelligent fluid management decisions to keep business moving.
“ARO is proud to now offer a complete system solution that helps manufacturers and operators manage fluid easily and intelligently, with less operator oversight required,” Wesley added. “Less time standing at the controller means more time on the floor making sure things are running smoothly.”
The new controller improves upon the already precise ARO EXP pump by ensuring the pump is fully primed, resulting in +/- 1 percent repeatability. It features an easy-to-use interface pre-programmed with eight languages and can:
• detect leaks
• operate two pumps simultaneously
• sense and respond to liquid levels
• accurately control proportions
• control flow-rates
Call us now to get control of your pumping process!
Last spring I was visiting with one of our customers in Middle Georgia.
They were having two problems with an application involving a Viking L4724 Positive Displacement Internal Gear pump. Basically the pump was being used to recirculate their material in a large storage tank. However, they also used it to introduce some additional material by adjusting some valves in their pipework.
The first issue was a loud racket being made by the pump when they started it up to add material to their process.
The second issue was the amount of time it was taking to pump down a 55 Gallon drum which is where the material comes from that they want to add to the recirculation tank.
When I approached their process with their engineer I asked him if it was ok if I stated the obvious, to which he replied “sure.”
The first thing I pointed out was the distance between the pump suction port and the Tee/Valve where they change the intake material was nowhere near long enough. Basic Pumping Principles 102, you need a straight run of pipe 10 times your pipe diameter to allow for proper friction loss before your liquid enters your pump. This was causing the pump to cavitate which was causing the racket they were hearing upon pump start up.
The next thing I pointed out was that they were using a 1” steel pipe connected to about 8 feet of 1-1/2” hose connected to their 2” Tee, located about 6” from their pump inlet, in order to pull the liquid out of a 55 gallon drum. Can you say starvation AND cavitation?
I spoke to their engineer and he agreed that these issues were a problem but they couldn’t be fixed and he wanted me to solve the two problems as best I could based on these conditions.
He felt that putting a VFD (variable frequency drive) on the motor of the pump would allow them to start it ‘softer’ and ramp up allowing material to get to the pump before it hit full speed and he figured that should stop the racket and possibly drain the 55 gallon drum a little bit quicker.
Well, the customer is always right. I told him that I didn’t think a VFD would solve his problems but if that’s what he wanted then that’s what we would quote him.
The moral of the story is, know your pumping basics BEFORE you build your pump system. A good foundation in pumping principles would have done wonders for their process and would have negated these issues from the beginning.
Don’t make this mistake yourself. If you have questions, call us. That’s what we are here for.
Many customers are becoming energy conscious and are reviewing existing production equipment to look for ways to save energy. One major item of consideration is the cost of compressed air. For fluid transfer requirements, many customers will use an Air Operated Diaphragm pump.
For a typical 2" AOD pump to transfer 50 GPM of light weight fluid with a discharge pressure requirement of between 40 to 50 psi and an inlet air pressure of 70 psi, it will require approximately 50 cfm of air (this converts to approximately 12 BHP). If the fluid is viscous and has a higher discharge pressure requirement, the inlet air pressure for the AOD pump can increase to 100+ psi and will require 25 percent+ more flow.
This was evidenced by my customer, RUSTOLEUM in Decatur GA who manufactures coatings. They were using a 3” AOD pump to transfer a viscous 1500 cps, high particulate metallic coating that is very abrasive. The AOD pump had an inlet air pressure of 120 psi and a discharge pressure of approximately 30 psi which resulted in a discharge flow of 40 GPM. The required cfm of air was approximately 60 cfm (15 BHP).
Due to the pulsation seen on piping and valves, they were also using a BLACOH 2” pulsation dampener. Because of the abrasive nature of fluid, the AOD pump required service with new wetted parts every 3 to 4 weeks which was totaling around $500 per repair.
The customer wanted to expand production with a required flow of 60 GPM and would need two 2” AOD pumps to accomplish this, which would be around 50 to 60 cfm for 30 GPM @ 120 psi (converts to 15BHP).
In an effort to reduce both the maintenance costs as well as the energy costs, a VIKING LS4124A 3” internal gear, positive displacement pump was supplied. We c-face mounted the pump to a speed reducer and drove the package with a Premium Efficiency 7.5hp 1750 rpm motor. The pump is typically supplied with carbon graphite bushings but we replaced those with hardened iron bushings; and we also converted the pump from a mechanical seal to packing, expecting a short seal life due to the abrasive nature of the fluid.
The Viking LS4124A pump is supplying a transfer rate of 65 GPM and is seeing reduced parts replacement. The transfer rate was reduced by almost 30% using the Viking PD pump compared with the AOD pumps. And the power requirement was reduced by 50 percent.
Based on this improved performance, Rustoleum has now converted their West Virginia plant from AOD pumps to VIKING positive displacement pumps for this same sand based, high viscous fluid.
RUSTOLEUM still uses various AOD pumps for their light weight water based fluids.
In street lingo "def" means something cool, hip, up-to-date.
In the world of diesel engines DEF defines the latest in reducing harmful exhaust emissions. DEF is an acronym for Diesel Exhaust Fluid, an important component that minimizes nitrogen oxides (NOx) in a technology called Selective Catalytic Reduction (SCR). DEF itself is a carefully blended aqueous urea solution of 32.5 percent high purity urea and 67.5 deionized water.
Small quantities of DEF, are injected into the diesel exhaust upstream of a catalytic converter where it vaporizes and decomposes to form ammonia and carbon dioxide. The catalyst them converts the nitrogen oxide into harmless nitrogen (N2) and water (H2O).
For industries that maintain fleets of diesel powered trucks and equipment with these systems, Finish Thompson (FTI) has just the pump to transfer DEF supplied to them in drums or totes to the truck holding tank. Finish Thompson DEF drum pumps are designed for years of reliable service while maintaining the strict purity requirements of DEF. The system, sold as a kit, includes a polypropylene pump tube to match the container size, your choice of motor (air or electric), a sealed bung adapter, eight feet of DEF dispensing hose and a stainless steel automatic shutoff nozzle. FTI also sells these components separately.
Separate kits are available with tube sizes for a five gallon bucket up to a 330 gallon tote. A choice of two pumps are available: an economical 5 GPM (EFP Series) or a high performance 10 GPM (PFM Series) version. The dispensing hose is made of EPDM elastomer and is peroxide cured and flushed with deionized water. The 19 mm shutoff nozzle is specifically designed for the on-board storage tank on the engine.
To sum it up a Finish Thompson drum pump is the most ‘def’ for DEF!