Industry News

Predicting Pump Failure Before it Happens

Somewhere in North America today, a pump that is responsible for delivering residential drinking water through a municipal pipeline will stop working. Whatever the cause, the result will be largely the same: water supplies will be diverted, lives will be disrupted, and emergency repair funds will be spent.

The good news is that events like these may not be typical for much longer.

Predicting Pump Failure

Thanks to a precipitous drop in monitoring technology costs and powerful new predictive analytics, it is now far easier—and less expensive—than ever to avoid pipeline, pumping and other system failures. And municipal water systems are the tip of the iceberg of beneficiaries. New stand-alone predictive maintenance solutions can be integrated into new and existing applications across a wide range of industries.

From Preventive to Predictive Industrial Pump Maintenance

Thanks to real-time asset condition monitoring, the ultimate benefit of these solutions is their ability to move organizations from a preventive maintenance model to a predictive approach.

Instead of following a predetermined schedule for maintenance and repairs, organizations that use these solutions can focus instead on the actual issues that are currently or might soon be affecting system performance. A sensor that picks up on changes in vibration, for example, might lead a maintenance team to maintain a motor bearing in lieu of performing general maintenance on a rigid schedule, producing substantial cost savings in the process.

All this information can be accessed from a browser-enabled computer or mobile device at a fraction of the cost of just a few years ago. Sensors and microchips that once cost more than $500 are now available for $25 or less. The cost to transmit and store data in the cloud has also been slashed by as much as 95 percent opening the door to new ways of doing business.

Even so, an organization is wise to develop a monitoring and analytics strategy before jumping in head-first. Rather than monitor everything, it may make better economic sense to deploy these technologies strategically on mission-critical systems with the greatest value or on those that pose the greatest risk.

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Common Pumping Mistakes

Why does a pump’s hydraulic performance differ from its published curve?

This is one of the most common questions about pump performance.

The answer to the question is often simple but can be difficult to sort out given the myriad possible causes. I offer the following discussion points as a guideline.

Common Pumping Mistakes

Check the Pump

First, check for the simple things, such as a restricted suction line, and make sure the pump is primed and not air bound. Remember, you cannot vent a running pump. The lighter air will stay in the middle of the casing and the heavier fluid will move to the outside. Does the pump have the correct rotation direction? Depending on the specific speed of the impeller, a pump running backwards will deliver about half the flow and head.

Air entrainment, even at just two to four percent, will air bind a standard pump. Ascertain adequate submergence (distance from liquid surface to intake centerline) to prevent vortexing (vortices lead to air binding) and a sufficient net positive suction head available (NPSHa) margin.

ANSI Pumps

In the case of American National Standards Institute (ANSI) pumps, check to see that the pump impeller clearance is properly set. Note one style of ANSI pump sets the impeller clearance to the stuffing box, while the other style sets to the casing. The pump may simply be worn out and the clearances have opened up, which will manifest as if the pump has a smaller impeller. The volute cutwater (aka “tongue”) will wear, resulting in reduced efficiency, and move the published best efficiency point (BEP) to the right on the curve. The cutwater is a pump flow regulation point and works in concert to match the volute flow to the impeller flow.

Suction Lift Pumps

In the case of a suction lift (where the fluid source is below the impeller centerline) check for air leaks into the suction system. Remember, the fluid will not leak out, but air will leak in. In a perfect scenario, the maximum suction lift at sea level is less than 34 feet. In the real world with friction and vapor pressure, it is less. Problems are more likely at higher altitudes above sea level, with warmer fluids and with vertical lifts approaching 30 feet. Practical lifts are usually under 26 feet.

When troubleshooting malfunctioning pumps, I often find the wrong impeller has been installed during maintenance, or the correct impeller is installed at the wrong diameter.

Centrifugal Pumps

A centrifugal pump is “dumb” and will operate where the system curve dictates. If a pump is not operating where it should, review the validity of the system curve. The system curve is an absolute summation of the system’s static head, pressure head, velocity head and friction head. The geometry of the system curve is directly related to the flow rate, pipe size, elevation changes and losses due to friction of all the components in the system. Note the system curve is dynamic and will change with tank elevation and system pressure changes. It will also change with valve position, system age, fouling and corrosion. Reliance on a system print to determine the system curve can also lead to errors. It is best to actually walk the system and see what is really there. I often find unauthorized piping branches, valves and elbows.

Manufacturer’s Pump Performance Curve

When a pump is operated at either end of its curve, there are issues like cavitation, separation and recirculation. A manufacturer’s pump performance curve is based on pumping water at ambient temperature (usually around 68 F), a specific gravity of 1.0, a viscosity of less than 30 centipoise (cP) and the assumption that the fluid is not a slurry. When pumping a fluid other than water, the curve may need to be adjusted/corrected for viscosity. The horsepower requirements (power consumption) will be different for different specific gravities.

Sometimes overlooked, the manufacturer’s curve is typically based on a stated speed, and the actual speed in the field is different. This speed differential will happen with induction motors that are not fully loaded or properly specified, since the motor speed will typically increase at lower loads. Speed differentials can also occur due to voltage variations. Look at the motor nameplate or contact the manufacturer for full load speed and the expected percent of slip. The advent of variable speed drives over the last two decades has made the speed difference issues more prevalent. Even 30 to 50 rpm will make a difference in the pump performance.

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Now Offering: Mission Magnum Pumps & Parts

We are the leading mission centrifugal pumps and parts distributors with vast experience and expertise in the sale, service and repair of centrifugal pumps. We provide a series of interchangeable Mission Magnum pump parts that provides a guaranteed unified quality. We offer and distribute casings (nuts, gaskets and studs), impellers, mechanical seal pumps and more.

Mission Magnum Pumps and Parts

The Magnum is designed with an open impeller containing wide-tipped vanes and a tangentially circular suction that allows the pump to produce smother flow pattern when managing abrasive fluids. The pump comes in aluminum bronze, stainless steel, hard iron, and MagnaChrome fluid ends. Due to their economical structure, Mission Magnum pumps can be unitized with diesel engines, electric motors, and all forms of hydraulic motors configurations.

Mission Magnum Centrifugal Pump

Shown is Magnum Centrifugal Pump

Benefits of Magnum Centrifugal Pumps

Magnum centrifugal pumps are equipped with wonderful features that provide invaluable benefits to the drilling industry. They include:

  • Receded casing casket for protection
  • Versatile stuffing box
  • No-adjustment mechanical seal with long-life that allows near zero leakage
  • Back vanes for a reduced collection at stuffing box
  • One piece casting box
  • Shaft sleeve that is replaceable
  • Stronger and thicker concentric casings
  • Duplex angular contact bearings
  • Front access drain that is easily accessible
  • Roller bearings of single rows for increased bearing life
  • Full pipe diameter for maximum efficiency and minimum turbulence

Contact us today for all your magnum centrifugal pumps and parts needs.

Have a Question?

Our pump engineering experts have been in the industry for awhile and will gladly assist you with any questions, concerns, or inquiries you may have regarding the pumps & pump parts we distribute @ 800.560.7867.

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Motor Control Centers Enhance Smart Pumping Systems

These advanced components connect with a networked automation system and provide more control and safety for protecting pump systems.

Modern motor control technologies have surfaced that address evolving smart pumping system requirements. They protect pumping systems by simultaneously providing a new level of diagnostics, energy awareness and control, as well as by enhancing operator safety.

smart pumping systems

System management has moved away from the equipment itself and into the control room. The components in motor control centers (MCC) offer advanced protection, efficiency and information, so that operators can provide more effective predictive maintenance.

Among the variety of solutions essential to the distribution of power, low-voltage MCCs are unique because they can be used for power distribution, as well as for the control and protection of motors. MCCs are traditionally the most effective way to group motor control, associated control, distribution and industrial communications equipment.

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10 Tips for Better Pump Life Management

When the whole plant unexpectedly shuts down, then the pump gets attention. A report presented by Occupational Safety and Health Administration (OSHA) shows that most workforce accidents occur when a plant is in an emergency (unscheduled) situation. If you want to increase reliability and reduce the high costs and safety risks associated with emergency shutdowns, adding gauges and managing the data are simple and inexpensive first steps.

pump life management

Gauges

Gauges will measure pump performance and display the differential pressure across the pump. That information, in conjunction with knowledge of the pump and system curves, will provide plenty of details about the health of the pump and system.

Pump Curves

The pump will operate at the point on its curve where it is intersected by the system curve. As the pump curve changes with impeller size, speed and wear (clearances open up), the system curve changes with wear, process control changes, corrosion and/or marine growth buildup.

10 tips providing guidance for using gauges to achieve better pump life management.

  1. Gauges are simple and relatively inexpensive. In addition to gauges, end users can adopt more current technology by substituting pressure transducers (digital gauges).
  2. Two gauges are recommended on the pump, one on the suction and one on the discharge. As a “Plan B,” use one differential pressure gauge. This is better than no gauges at all.
  3. It is advisable to use a compound pressure gauge or absolute pressure gauge on the suction side.
  4. It is recommend using absolute pressure gauges to avoid error in calculating the differential pressure.
  5. Several companies specify that gauge “taps” (penetrations drilled and tapped) be put on the pump flanges. It may be easier and less expensive to have them on the adjacent piping.
  6. The size of the pipe and the flow rate should be noted and then understand that gauges (transducers) measure pressure, not velocity. Should you place gauges on the adjacent piping, be aware that differences in elevations will need to be compensated to a common datum point, usually the pump (or impeller) centerline.
  7. A pressure gauge placed four to six pipe diameters downstream of the discharge flange will yield a more accurate head reading. Note that the gauge should be placed before the isolation and check valve to be accurate.
  8. Many facilities do not use gauges because of issues with vibrations and pressure pulsations. The use of snubbers, loops, capillary tubes and isolation valves is recommended to mitigate the problem.
  9. It is noted that some plants do not incorporate gauges for a variety of reasons. For those facilities, it’s advisable that at least an isolated/capped or plugged penetration where a gauge, transducer or digital gauge can be installed.
  10. Select the gauge (transducer) to be in the correct pressure range for the application. Gauges are most accurate in the middle one-third of their total range. Do not forget temperature ratings and compensation in that selection process.

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Have Questions? Give Us a Call.

If you ever have a question regarding industrial pumps that you are looking for more information on, never hesitate to call one of our trained experts @ 800.560.7867.

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Launch of MTeq for Mud Pumping

mud-pumping

Energy Recovery, Inc., a leader in pressure energy technology for industrial fluid flows, recently announced the release of MTeq, a pumping solution designed to increase productivity and reduce operating costs in the mud pumping process in oil & gas drilling applications by rerouting abrasive fluids away from high-pressure pumps.

In conjunction with the MTeq product launch, Energy Recovery also announced a partnership with Sidewinder Drilling LLC as its first early-stage partner for the solution.

MTeq is installed as a barrier between the mud pits and the pumps, thereby aiming to allow the pumps to process clean, particulate-free fluid, and not the particulate-laden fluid that lends to component failure.

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New SPX FLOW Manufacturing & Distribution Center

This 4 minute video lets you tour SPX FLOW’s new manufacturing and distribution center. The new facility – located in a modern, well connected industrial zone near Bydgoszcz, Poland – provides us with the ability to streamline their manufacturing processes and significantly improve product lead times.

Their investment in the facility and advanced manufacturing equipment confirms a commitment to exceed customer’s expectations. In this state-of-the-art facility, SPX FLOW manufactures and assemble a complete range of hygienic valves, pumps and plate heat exchangers to handle even the most challenging applications. You can rely on the performance, quality, and on time delivery of equipment from SPX FLOW.

SPX Pump & Parts Distributor

We provide many different SPX pumps & pump parts:

  • SPX Industrial Pumps
  • SPX Sanitary Pumps
  • SPX Metering/Dosing Pumps
  • SPX Johnson Pumps
  • SPX ClydeUnion Pumps
  • SPX Pump Parts
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In the News: Global Demand for Diaphragm Pumps Expected to Grow

industrial diaphragm pump newsAccording to a leading global technology research and advisory company, Technavio, the demand for diaphragm pumps is expected to grow by more than 5% by 2020.

What is triggering the growth?

Based on the report, the main reasons for the expected growth is due to the availability of low-cost labor and raw materials.

What industries will benefit the most from this news?

Specifically, the chemical and petrochemical industries will benefit the most from this news and this includes methanol, ethylene, or fertilizer plants all of which utilize diaphragm pumps almost exclusively for various applications that involve transferring fluids from one process to another. Diaphragm pumps are vital to this industry.

However, other industries will also benefit. Namely:

•Oil & Gas (expected to grow by ~3%)

•Pharmaceutical

•Food & Beverage

•Agriculture

View all of the industries that Pump Engineering Co. serves.

Who are currently the top leaders for Diaphragm Pumps?

As reported by Technavio in the report, the current key players in diaphragm pumps are as follows:

•Dover
Flowserve
•Grundfos
•LEWA
•Xylem

Pump Engineering Co. is a proud distributor of Flowserve industrial pumps.

“Rise in application of the diaphragm pumps in the key industrial segments, like wastewater treatment, pharmaceuticals, food processing, and other sectors will help the diaphragm pump market to grow during the forecast period. The growth of the market is also attributed to its increasing application in industrial sectors of developing countries, such as India and China. The initiatives, like FDI regulations and deregulation of the pricing policy, taken by governments in these countries will boost industrial development, especially in the power, agriculture, oil and gas, chemical, infrastructure, and F&B sectors,” says Anju Ajaykumar, a lead analyst at Technavio.

Report Source.

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Proudly Serving Southern California!

Since 1946, Pump Engineering Company has been providing Southern California with pumping equipment from industry leading manufacturers. We are conveniently located in the area of Santa Fe Springs, CA. This allows us to offer sales, engineering, troubleshooting, service, and repair to our clients. Utilizing factory trained technicians to handle all of your industrial pumping requirements. With an extensive inventory of pumps and parts, Pump Engineering Company offers quality pumps and service for your brand.

pumps, southern california, manufacturer

 

For more information contact us for prompt service 800.560.7867.

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Industrial Pump Types and Their Main Benefits & Applications

industrial pump types benefits applications

There are many types of industrial pumps offered for a variety of applications. Each type of industrial pump comes with advantages not offered by other pumps. As experts in industrial pumps and rotating equipment since 1946, we wanted to provide a quick easy-to-digest way of understanding what advantages each industrial pump possesses.

Main Benefits, Advantages, & Applications of Each Type of Industrial Pump

1. Centrifugal Pumps

The best choice for lower viscosity liquids and high flow rates.

2. ANSI Process Pumps

Incorporates dimensional standardization, which allows for the piping, foundation, and design to be completed before pump suppliers are even selected. Also features more material options than other types.

3. API Process Pumps

Meets all API 610 requirements which assures safety & reliability for high pressure, high temperature hydrocarbon applications.

4. Axial Flow Pumps

The best choice for achieving a very high flow rate with very low head.

5. Booster Pumps

Allows for the build up of additional pressure required to move liquid over long distances.

6. Piston Pumps

The best choice for applications that involve abrasive liquids.

7. Progressive Cavity Pumps

Sometimes referred to as “the pump of last resort” because it is able to handle difficult liquids that other pumps are unable to accommodate.

8. Screw Pumps

These pumps feature the highest flow rate of positive displacement pumps.

9. Gear Pumps

The best choice for clean oil applications with few moving parts & simple construction.

10. Lobe Pumps

The best choice for sanitary applications that pump viscous liquids or liquids that contain fragile solids, featuring no metal-to-metal contact within the pump.

11. Diaphragm Pumps

One of the most versatile choices handling a wide range of liquids that are sealless and can run dry without damage to the pump.

12. Vertical Sump Pumps

One of the most affordable, cost-effective sump pumps offered.

13. Vertical Turbine Pumps

The best choice for deep wells.

14. Submersible Pumps

The best choice for areas prone to flooding. Also these pumps eliminate column shaft and bearings found in column sump pumps.

15. Self-Priming Pumps

Main advantage: no need for external priming!

16. Multistage Pumps

Currently the best way to get high pressure with a centrifugal pump with lower thrust loads.

17. Magnetic Drive Pumps

No mechanical seals & are certain to be leak-free in design.

18. Horizontal Split Case Pumps

One of the least likely pumps to cavitate that features much higher flow rates than end suction pumps.

Need Help on Deciding What’s Best For You?

A complete list of the industrial pump types we offer may be found here. If you need assistance deciding on what industrial pump type should be used for your business, then feel free to reach out to us @ (800) 560-7867 or contact us online.

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