Industry News

Maximizing ROI on Rotary Gear Pump Service

Pumping equipment in any large processing facility represents a massive investment, since you require dozens of pumps to move water and other process fluids from one point to the next. Moreover, the annual maintenance and service costs for these pump systems typically ranges from 2% to 5% of the initial value of those systems.

Although the range seems acceptable, the costs can amount to millions of dollars or more over the life of the machinery or facility. But the cost of service and maintenance involves a lot more than getting replacement parts and paying for labor and equipment. You also need to take into account that any down time of a refinery, plant, or wastewater facility has a direct impact on the bottom line – profits.

Maximizing ROI on Rotary Gear Pump Service

ROI on Pump Service & Repair

The maintenance costs for one-time repair, even on the higher end (5%), tend to be negligible compared to the lost earnings from the down time and process restart. So the true value of maintenance operations should be determined based on the facility’s uptime. The easier it is to maintain the equipment, the faster it gets done.

Simple maintenance processes give plant operators/technicians greater flexibility to schedule preventative maintenance between shifts or any other time when it is least disruptive.

Considering that rotary gear pumps are typically used to pump corrosive or harsh liquids, most applications prefer the sealless designs. Their solid construction implies that there are no areas of weakness for the harsh chemicals to leak and destroy the pump or surrounding equipment. This also translates to easier maintenance.

Technology vs. Experience

As the demographics for operators and engineering personnel continues to change, there is a gradual loss of experience at the worksite that can be offset by the use of new, smart technologies that use sensors to alert operators of potential problems before any breakdowns occur.

The combination of simple pump designs and fewer parts to maintain with sensing technology and intuitive access are the key to successful preventative maintenance programs and equipment longevity.

Pump Engineering Co. for Rotary Gear Pumps Repair

Whether you have an emergency situation or if you have any further questions regarding our Rotary Gear Pump repair and services, please contact us @ 800.560.7867 or fill out our online contact form.

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Horizontal Split Case Pumps and Their Applications

A horizontal split case pump is a unique type of centrifugal pump whose casing is divided into two distinct chambers, which is different from inline or end suction pumps that are assembled with the suction nozzle, discharge nozzle, and casing in one chamber.

Horizontal Split Case Pump

The casing can be split vertically or horizontally, relative to the impeller, which gives you either a vertical split case or a horizontal split case pump, respectively. Some manufacturers also offer custom configurations to optimize the pump for specific applications.

Horizontal split case centrifugal pumps are designed with the suction and discharge nozzles in the bottom half of the casing, side by side, while the impeller shaft is positioned between two bearings, one on each side.

This rugged but simple design is particularly suitable for higher flow applications as it reduces thrust loads and allows for operation over a broad range of capacities. With proper application, HSC pumps offer minimal power consumption, low maintenance costs, and extended service life.

Other design features of HSC pumps include:

  • A double suction impeller that offers lower axial thrust and superior Net Positive Suction Head (NPSH)
  • Double volute casing to minimize radial bearing loads
  • Dual pump seals to seal suction pressure

Common applications of horizontal split case (HSC) pumps

These pumps are typically used to carry low-viscosity liquids such as clear water and unsaturated wastewater from industrial processes at average heads.

HSC pumps can be used for higher flow rate applications that are not suitable for end suction pumps, such as fire pumps, portable water distribution, plant make-up water, pipelines, cooling water, and other industrial process flows with fairly thin fluids.

Depending on your specific application, you can opt for either the single stage HSC pump with a head of up to 550 feet at 140,000 gpm, or the multi-stage HSC pump with a maximum head of 2.200 ft, max. operating pressure of 740 psi, and flow range of up to 2,000 gpm, which is suitable for heavy duty, high pressure applications.

Keep in mind that HSC pumps are not suitable for transporting thick or viscous liquids, as well as those containing solids.

Pump Engineering Co. for Horizontal Split Case Pumps Repair

Whether you have an emergency situation or if you have any further questions regarding our Horizontal Split Case Pump repair and services, please contact us @ 800.560.7867 or fill out our online contact form.

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Sanitary Pump Repair vs Remanufactured vs Replacement

When you have a worn sanitary pump, your options include repair, remanufacture, or replacement. But which option is right for you?

Sanitary Pump Repair vs Remanufactured vs Replacement

Authorized Pump Repair

Worn sanitary pumps can be repaired and re-installed. But repair is not always a valid option. Upon receiving your pump, the sanitary end and gearcase are inspected to determine the cost of restoring the pump within acceptable tolerances or specifications. The cost of repair is typically lower than that of a factory remanufacture, though this depends on the condition of the pump.

Some reasons to repair your pump include:

  • Quick turnaround and minimal down time
  • Can be done more than 3 times (unlike remanufacturing) to extend the life of your pump
  • Reducing your expenditure by postponing the need for a new pump

The repair work is usually quite extensive, and may involve complete service of the equipment for it to function like new.

Factory Remanufactured

This option is recommended a maximum of two times. When you ship your pump to the factory, you will receive a different one that has been remanufactured.

The process of remanufacturing may involve:

  • Inspecting and replacing all parts in the gearcase with genuine replacement parts as needed
  • Checking the clearances in the sanitary end and milling the body .030 or .060 to form new-like surfaces
  • Installing oversized rotors that fit in the re-machined body

Due to the oversizing process, all the parts of a remanufactured sanitary pump are a matched set, and should not be assembled with parts from other new or remanufactured pumps. The remanufactured pump is backed by a new pump warranty.

So When Should You Get a New Replacement Sanitary Pump?

If pump wear can be fixed without milling the cover or body, then the pump can be successfully repaired. But if wear to the pump cover or body prevents it from performing as required, then it should be remanufactured.

Purchasing a new pump is not an economical option, especially if the pump can be repaired or remanufactured. But after the pump has been factory remanufactured twice, and the extent of wear to the cover and body won’t allow the pump to operate at an acceptable level of performance, then it’s time to get a new one.

Keep in mind that the extent of wear or clearance within your sanitary pump depends on the specific application. Always consult a professional to determine the best cause of action with regard to repairing, remanufacturing, and replacing the pump.

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Applications of ANSI Centrifugal Pumps

There are different types and brands of centrifugal pumps on the US market, but only ANSI centrifugal pumps follow the standard dimensions as regulated by the ANSI B73.1 or ASME B73.1 standards.

ANSI Centrifugal Pump

These minimum standards are imposed by two different bodies: the American National Standards Institute (ANSI) and the American Society of Mechanical Engineers (ASME), and apply to all horizontal, single-stage, and end suction pumps that are similar in size, regardless of the brand, provided that the dimensions for the envelope and interface match.

What are the ANSI B73.1 Standards?

The ASME B73.1 standards are essentially guidelines that apply to specific designs of process pumps, including single stage, end suction, centerline discharge, and horizontal.

For convenient installation and service, these pumps are designed to offer dimensional interchangeability across the range. In fact, the standard is more or less a guarantee that all ANSI-designated centrifugal pumps of a similar size have interchangeable input shafts, discharge nozzles, size and position of suction, mounting dimensions, baseplates, and foundation bolt slots.

The ASME B73.1-2012 standard is similar in that it is intended to facilitate the installation, service, and repair of horizontal end suction centrifugal pumps. However, this standard is also meant to improve the durability and safety of ANSI B73.1 centrifugal pumps.

The Allure of ANSI Centrifugal Pumps

The fact that ANSI centrifugal pumps are designed according to the same minimum standards allows users to use designated and matching pumps and brands interchangeably without being required to redesign or change the piping location, coupling, motor attachment, or even the bedplate dimensions. You should, however, keep in mind that the pumps are fabricated using different materials, including non-metals and alloys for use in corrosive applications.

There are a couple of challenges of ANSI centrifugal pumps, like the fact that they can only be used to move low viscosity liquids, meaning they’re not recommended for conveying oils and other thicker liquids. Also, ANSI pumps are required to meet one standard, which can make it hard to find matching replacement parts for other types of centrifugal pumps.

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How To Troubleshoot a Chemical Metering Pump

The first step to ensuring trouble-free operation from your metering pump is seeking professional equipment recommendations prior to purchase and installation. Your installer can supply custom parts of the system, and coordinate the final installation. A typical installation process may include plant layouts and drawings, mechanical schematics, manuals, and even field training if needed.

Metering Pump

But even with proper installation and maintenance, the kind of work done by a metering pump will result in gradual wear, breakdown, and emergency repair. Some of the common problems include:

  • Loss of chemical residue – Can be caused by using a very low pump setting, scaling at the point of injection, or allowing the solution container to run dry.
  • Excess chemical – Can be caused by using a very high pump setting, using a very rich chemical in the solution tank, or siphoning of chemical into the well or main line.
  • Leakage at tubing connection – Usually due to worn tube ends or chemical attacks.
  • Failure to pump – This problem can be caused by many things, like a leak in the suction side of the pump, low setting on the pump, a ruptured diaphragm, low solution level, the valve seats not sealing, a cracked or broken pump head, the pump head containing air or chlorine gas, a voltage drop, or a breakdown or malfunction of the wiring and electronic control board.
  • Pump losing prime or refusing to prime – This can be caused by a dirty check valve, ball checks not sealing properly, excess pressure at discharge, or excess suction lift height.

With proper training, most in-house technicians can prevent these problems from arising through routine maintenance. That said, professional service and repair work is recommended at regular intervals to replace worn parts and/or rebuild and upgrade the system if need be. If done right, rebuilding your metering pump should carry the same warranty as a brand new one but without the extra cost.

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Types of Sump Pumps for Industrial and Commercial Applications

Vertical sump pumps are best suited for fitting in narrow and shallow sump pits, because they turn on the pump more often. This means that the pit gets emptied more frequently. However, this also means that you need to keep the pump motor running at all times to reduce the risk of flooding.

Vertical Turbine Pump

When designing industrial or commercial property, one of the things that you need to account for is proper drainage and sewage disposal. Storm water and sewage flowing through the ground may penetrate any existing cracks and reach your building’s foundation. This would not only damage the foundation and walls, but also flood the underground level and destroy your inventory, equipment, and other items below ground level.

With a vertical sump pump, this never has to be a problem for you. Simply install the slump pump in the sump pit, and all the water or sewage below ground level will flow into the pit from where it can be pumped out before it overflows.

There are other types of sump pumps available for commercial and industrial applications, including:

1. Submersible pumps

These are designed to sit in the groundwater, which also helps with cooling to prevent overheating. The pump is installed in the sump pit.

2. Pedestal pumps

Unlike submersible pumps, pedestal pumps are air-cooled. They need a lot of space for optimal air circulation to prevent overheating.

These pumps have a simple design, with a drain pipe through which the material (water, slurry, or sewage) is pumped from the pit. They run 24/7, but often require a type of float switch for activation when the material level drops beyond a certain point. The common float switches include:

  • Tethered switches – they are attached to the pump, and mostly used for deep and wide sump pits
  • Vertical switches – they are fitted in narrow, shallow sump pits, and tend to activate more often to prevent the shallow pit from overflowing.
  • Electronic switches – they rely on electrical components to read the level of the material in order to turn the pump on or off.

Finding the right switch is nearly as hard as finding the right sump pump for your application. Please seek help from a reputable and professional company to identify the best equipment and components for your specific application.

Pump Engineering Co. for Vertical Sump Pumps Repair

Whether you have an emergency situation or if you have any further questions regarding our submersible pump repair and services, please contact us @ 800.560.7867 or fill out our online contact form.

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Industrial Centrifugal Pumps Repair, Service, & Maintenance

Centrifugal pumps are the most common industrial pumps used in processing plants and municipalities to supply water or remove effluent. They have a simple design, are cost-effective, and have fewer moving parts, which reduces the need for maintenance.

Many pump breakdowns are due to simple, needless failures, like the loss of clamp load which can cause misalignment and bearing failure. Simple, basic maintenance can prevent similar avoidable failures from happening.

Industrial Centrifugal Pumps Installation

Industrial Centrifugal Pumps Repair, Service, & Maintenance

Centrifugal pumps are mostly used for applications that require high flow rates. The steady fluid delivery prevents pulsations that are common with positive displacement pumps.

When assembling your pump, there are several simple steps that can be taken to reduce the probability of common failures or to eliminate it altogether, and make future disassembly much smoother.

First, when choosing an industrial centrifugal pump, it is best that you work together with our pump repair specialists who will ensure that the installation is done correctly, and help to institute a proper maintenance program. In doing so, you can enjoy optimal performance of your equipment, prolong its life, and maximize the return on your investment.

Centrifugal Pump Repair and Maintenance

Repair is a critical component of pump maintenance. Owing to the harsh operating parameters and environment, pump parts are prone to wear, corrosion, erosion, leaks, and other kinds of damage. It is important to create a proper maintenance program, and get the right parts based on the pump brand, model, and size to restore the damaged ones.

A routine pump maintenance routine may involve the inspection of:

  • Oil seepage – to prevent the loss of oil
  • Impeller and casing wear – to rebuild worn areas and restore the impellers and pump casing
  • Shaft wear – to restore a worn shaft to the original condition
  • Corrosion – to prevent corrosive damage to external components
  • Keyway wallow – to repair wallowed out keyways

It is best to engage the services of a professional centrifugal pump contractor for proper repair, maintenance, and service of your industrial centrifugal pump.

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Industrial Submersible Pump Repair, Service & Maintenance

Just as the name suggests, a wet well submersible pump operates when submerged in the fluid material such as water or sewage. The motor is usually sealed hermetically and encapsulated in the pump casing to maintain proper operation even when completely submerged in the material.

However, there is another kind of submersible pump that does not need to be submerged to pump the material. Submersible dry pit pumps are usually built below ground level, but are not flooded by the material. They should be carefully placed and protected from flooding, which could damage the motor. The submersible pump is usually cooled with a cooling jacket.

Industrial Submersible Pump Maintenance and Repair Services

Industrial Submersible Pump Repair, Service & MaintenanceSubmersible pumps are well designed to prevent the material being pumped from getting into the electric motor. The motor is placed in a water-tight compartment that is filled with oil or air.

These pumps are very common in industries because they are compact, which reduces the cost of installation. They also don’t have many wearable parts like housings, bearings, and shafts, which reduces downtime associated with repair and maintenance.

That said, some basic maintenance and repair is necessary to ensure optimal performance and longevity of the pump, including:

  • Onsite troubleshooting
  • Bead blasting
  • Thorough cleaning of all parts and components
  • Full disassembly and inspection
  • Precise measuring and non-destructive testing
  • Part fabrication or rebuilding as need be
  • Impeller and rotor precision balancing
  • Application of custom impeller coatings
  • Motor analysis and diagnostic testing/analyzing

Use the Right Submersible Pump for Longevity

It is important to choose the right size and capacity of your industrial submersible pump for optimal performance. The ideal pump depends on:

  • Head condition
  • The required GPM discharge
  • Friction losses from fittings, valves, and distance

In addition to getting the right pump size, you may also choose an automated one that comes with an inbuilt float switch – and control panel for larger systems – for greater material flow control.

Pump Engineering Co. for Submersible Pumps Repair

Whether you have an emergency situation or if you have any further questions regarding our submersible pump repair and services, please contact us @ 800.560.7867 or fill out our online contact form.

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Avoid Lubrication Maintenance Mistakes

Problems cause wear and damage, create friction and heat, and can lead to costly repairs.

by Matthew McCormack

 

Avoid Lubrication Maintenance Mistakes

Avoid Lubrication Maintenance Mistakes

Proper lubrication of rolling bearings in rotating machinery—pump systems included—is essential in realizing optimized performance and reliability. Whether grease or oil, lubricants serve to prevent wear and damage between a bearing’s rolling and sliding contact surfaces, reduce friction and heat generation, help protect against corrosion, and help keep out contaminants.

The right lubricant for an application should always be supplied in the right quantity at the right time. This may seem intuitive, but adhering consistently to this practice can be challenging, especially when bearings are lubricated manually.

Many manual-lubrication technologies—some quite advanced and user-friendly—have been developed to aid the process. But what if lubrication points are difficult to access? What if too much or too little lubricant is dispensed? What if the number of points requiring lubrication is especially high? Typically, there can be upwards of 7,500 individual lubrication points at a paper mill, 4,000 for a steel mill, 3,500 for a refinery, and 2,000 for a cement mill—all requiring service and vigilance over time.

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Tips for Choosing Reliable Chopper Pumps

High-velocity mixing nozzles can add oomph for difficult processing areas.

by Derek Vaughan 

Whether caused by “flushable” wipes, foreign objects in the effluent stream or floating grease mats, wastewater treatment plant operators experience costly and disruptive clogs to pumps, pipes and other systems.

“It’s a huge problem—an absolutely horrible problem,” said Frank Stuemke, of the Minnesota Rural Water Association, in a Minneapolis Star Tribune story on flushable wipes.

In fast-growing Tacoma, Washington, (population 208,000) the city’s wastewater treatment utility spends approximately $250,000 annually unclogging pipes and de-ragging pumps, reports the Tacoma News Tribune. In addition to wipes, flushed objects have included dentures, clothing and even a 3-inch hard-plastic Elmo character child’s toy that jammed a pump.

While part of the solution is educating people to not flush problematic items, education only goes so far, especially when compliance is less than 100 percent and other problems like greasy, floating mats also disrupt plant operations.

To keep wastewater flowing freely and reduce maintenance costs, more municipalities are installing chopper pumps as standard equipment in their wastewater systems.

Tips for Choosing Reliable Chopper Pumps

Advances in Chopper Pump Technology

Reliable chopper pumps have been available for more than 50 years.

These centrifugal pumps chop incoming solids prior to pumping to protect the pump from clogging, and in turn benefit downstream components, processes and the environment.

Pump Capabilities

High-performance chopper pumps can process virtually any heavy-duty solid that finds its way into the sewage stream—from wipes to rags, and even bulky items like nylon rope, garbage bags and plastic bottles.

Depending on the specific pump, chopper pump performance includes the ability to:

  • accommodate flows that are greater than 13,000 gallons per minute (gpm)
  • integrate with discharge sizes up to 16 inches
  • handle dry suction lifts that are up to 22 feet
  • achieve hydraulic efficiencies greater than 75 percent

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