- 2nd August 2006 -

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Upgrading pump monitoring for process efficiency using flow switches and flow conditioners

Getting the best possible process performance from a pump system is fraught with dangers - including velocity distortion, pressure fluctuations, and low flow or dry running conditions. Jim DeLee looks at some of the impediments to a smooth flow and explains how flow conditioners and flow switches can help ease the path to better process efficiency.

Optimizing your process for productive operation, including the pump, and protecting the pump against common hazards, are two of the smartest ways that engineers and technicians can help their plant operations. These efforts will improve end-product or batch quality, cut the material costs, eliminate waste and reduce maintenance costs. Taking good care of your pump always delivers a positive payback and there are some simple strategies that can be employed - starting with an analysis of process media flow rates.

Protecting your process

With today's focus on turning plants into 24/7 lean operations, pumps in most plants are running near capacity to keep up with material through-put objectives and demand in many industries - such as petrochemicals. One of the most common hazards of efficient pump operation is irregular material flow, which can result in three negative conditions: (1) flow turbulence, (2) low flows, or (3) dry running conditions.

Controlling material flow ensures that pumps operate efficiently, moving stock or products with the least possible expenditure of energy while reducing maintenance requirements and extending life. Failing to control material flow adequately can lead to some unwanted conditions, such as cavitation, pump bearing failure or even seal failure. The first problem - cavitation - can reduce capacity or even cause quality problems. Losing a bearing or a seal can lead to pump shut-down, possibly process line shut-down and unfavourable conditions could get worse the further you take this type of scenario.

Analyse the flow

Protecting your process and pump begins with analysing the flow to make sure the media is flowing regularly at the pressure required by the pump with a minimum headloss. Any number of process conditions can cause irregular flow, such as turbulence, temperature changes, unwanted air ingestion, etc. The problems of irregular flows and turbulence, in particular, can be especially challenging to solve, because eliminating the root causes are often difficult to impossible - so you need a 'workaround' strategy.

Nothing can damage a pump faster than the build-up of heat from low flow or dry running conditions, which occurs when liquid flow dramatically slows down or stops flowing altogether through the line or the pump. When the liquid isn't there to provide cooling, the heat can destroy a pump's bearings or seals. If repair is even possible, it is going to be a very expensive proposition. Of course, such dramatic failures also often ruin the material being processed or reduce process line capacity.

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Next page: Eliminating irregular flows

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