http://www.engineeringnews.co.za
  SEARCH
Login
R/€ = 14.15Change: 0.05
R/$ = 11.58Change: -0.02
Au 1195.87 $/ozChange: -1.05
Pt 1197.50 $/ozChange: 0.00
 
 
Note: Search is limited to the most recent 250 articles. Set date range to access earlier articles.
Where? With... When?








Start
 
End
 
 
And must exclude these words...
Close Main Search
Close Main Login
My Profile News Alerts Newsletters Logout Close Main Profile
 
Agriculture   Automotive   Chemicals   Competition Policy   Construction   Defence   Economy   Electricity   Energy   Environment   ICT   Metals   Mining   Science and Technology   Services   Trade   Transport & Logistics   Water  
What's On Press Office Tenders Suppliers Directory Research Jobs Announcements Contact Us
 
 
 
RSS Feed
Article   Comments   Other News   Research   Magazine  
 
 
Feb 27, 2013

Company Announcement: The benefits of pump system optimisation

Back
Flow|PROJECT|Pumps|SKF|SKF Energy Monitoring Service - Pump Systems|System|Systems|Energy|Energy Cost Savings|Energy Efficiency|Energy Loss|Energy Savings|Energy Transfer Efficiency Falls|Energy Use|Equipment|Flow|Machinery Breakdowns|Maintenance|Service|Services|Systems|Wasted Energy|Power|Bearings|Operations
Flow|PROJECT|Pumps|SKF|System|Systems|Energy|Equipment|Flow|Maintenance|Service|Services|Systems||Power|Bearings|Operations
flow-company|project|pumps|skf|skf-energy-monitoring-service---pump-systems|system|systems-company|energy|energy-cost-savings|energy-efficiency|energy-loss|energy-savings|energy-transfer-efficiency-falls|energy-use|equipment|flow-industry-term|machinery-breakdowns|maintenance|service|services|systems|wasted-energy|power|bearings|operations
Download PDF
SKF South Africa (Pty) Ltd (0.11 MB)
 

For most process industries, rotodynamic pumps represent a key component of their business processes. Too often, however, many facilities will take a “fit and forget” approach to maintenance of these vital pieces of equipment – at least until a critical repair is needed. There can be severe cost penalties associated with this approach. Some of the most significant include reduced productivity, and higher than necessary energy and maintenance costs. A carefully planned and implemented optimization program can help alleviate these unnecessary costs.

Generally speaking, optimization leads to reductions in energy use, thereby resulting in lower operating costs.  And while it is often the anticipated energy cost savings that are used to justify a pump improvement project, the fact is, benefits often extend well beyond energy savings. For example, shaft misalignment is responsible for up to 50% of all costs related to rotating machinery breakdowns. Accurately aligning shafts can prevent pump breakdowns and reduce unplanned downtime that results in a loss of production.

The point at which the highest proportion of energy from the shaft of a pump is transferred to the fluid being pumped is the Best Efficiency Point (BEP) of that pump.  At this point, internal forces in the pump are minimised.  As the operating point of a pump moves away from the BEP, this energy transfer efficiency falls and axial and radial forces increase.  Although some energy loss is inevitable (for instance, friction at wetted surfaces, at seal faces and within bearings) some of the energy that is not being transferred from the shaft to the fluid is wasted.  Of this wasted energy, some is lost by internal recirculation within the pump and some as heat or vibration.  These are destructive forces, and so the relationship between reliability and energy efficiency is clear – as more energy is wasted, destructive forces increase in intensity, so reliability is reduced

Case Study:  Energy savings with alignment optimization in pumps


A customer experienced high vibration levels on 12 pumps, resulting in excessive consumption of both spare parts and energy.  An SKF condition monitoring program with SKF Microlog Analyzer showed that the high vibration levels were clearly due to misalignment. Using the SKF TKSA 40 system technicians corrected the misalignment and optimized the electric motor.  Measuring energy consumption before and after alignment for the 12 pumps demonstrated an average of 8% energy savings (maximum of 20% in some cases) total kwH/year, along with reduced vibration levels and increased reliability.

In addition to higher maintenance costs, the costs of unreliability due to forced shut downs can be high.  The cost of unplanned shutdowns vary, and in many cases are difficult to quantify.  During a one-year survey by a major paper manufacturer at several of its mills, 101 pump reliability incidents were reported, costing a total of $5 million.  Although the value of each of these varied, the average cost per breakdown was almost $50,000.

The SKF Energy Monitoring Service - Pump Systems is designed to help pump operators track efficiency, as well as actual operating efficiency relative to BEP.  Periodic measurements of pressure, flow and power for each pump being tracked provide the data needed for the analysis, which is completed by SKF @ptitude software.  This is based on SKF’s Operator Driven Reliability concept and provides plant operators with the information they need to establish the optimisation opportunities available within their pump systems.  In addition, it can be incorporated into any condition monitoring program. In fact, SKF recommends that condition monitoring programs be adapted to include this data, as condition monitoring alone does not provide all the information needed to assess the health of a pump: energy efficiency is a key component of the information needed. 

Pump system optimisation provides real opportunities to improve reliability and to reduce costs.  There are many tools and training courses available to help provide the knowledge needed to implement a program to realise these opportunities.  Where investment is needed to capture the benefit, the full array of cost savings should be estimated to provide a realistic ROI for that investment.  Given that energy costs are by far the largest component of the life cycle costs of owning a pump, plant operators owe it to themselves to assure the highest level of pump optimization attainable. By working with the SKF Energy Monitoring Service - Pump Systems to incorporate the right tools and services into their condition monitoring programs, plant operators can go a long way toward maximizing their pump operations.

Comment Guidelines (150 word limit)
 
 
 
 
 
 
 
 
Other Announcements News
The University of the Western Cape reports that its Fortinet security solutions are proving so efficient that no security incidents have occurred to date this year. Elroy October, Systems Administrator at UWC’s central IT department, joined the central IT department...
EDEN PRAIRIE, MINN. … Power management company Eaton today announced the launch of Dura-KoteTM plating technology, which delivers a significantly higher level of corrosion resistance for Eaton’s carbon steel fluid conveyance products. Eaton’s carbon steel fluid...
The Financial Service Board released the Retail Distribution Review on November 7th, 2014. The review is based on the framework of Treating Customers Fairly and proposes 55 policy decisions in order to alleviate issues such as poor customer outcomes and mis-selling...
More
 
 
Latest News
China appears to have been routinely underestimating output from its sprawling steel sector, with official figures for last year alone 40-million tonnes below a key industry estimate - an amount equivalent to Germany's entire annual production. Beijing has vowed to...
Lumwana, Zambia
Canada’s Barrick Gold Corp will suspend operations at its Lumwana copper mine, in Zambia’s Northwestern province, after the country enacted legislation that raised the royalty rate on openpit mining operations from 6% to 20%. TSX- and NYSE-listed Barrick, the world’s...
The Labour Court in Johannesburg has set aside the 2011-2014 metal sector wage agreement, the National Employers' Association of SA (Neasa) said on Thursday. The 2011-2014 wage deal was the result of an agreement between the Steel and Engineering Industries...
More
 
 
Recent Research Reports
Liquid Fuels 2014 - A review of South Africa's Liquid Fuels sector (PDF Report)
Creamer Media’s Liquid Fuels 2014 Report examines these issues, focusing on the business environment, oil and gas exploration, the country’s feedstock supplies, the development of South Africa’s biofuels industry, fuel pricing, competition in the sector, the...
Water 2014: A review of South Africa's water sector (PDF Report)
Creamer Media’s Water 2014 report considers the aforementioned issues, not only in the South African context, but also in the African and global context, and examines the issues of water and sanitation, water quality and the demand for water, among others.
Defence 2014: A review of South Africa's defence industry (PDF Report)
Creamer Media’s Defence 2014 report examines South Africa’s defence industry, with particular focus on the key participants in the sector, the innovations that have come out of the sector, local and export demand, South Africa’s controversial multibillion-rand...
Road and Rail 2014: A review of South Africa's road and rail infrastructure (PDF report)
Creamer Media’s Road and Rail 2014 report examines South Africa’s road and rail transport system, with particular focus on the size and state of the country’s road and rail network, the funding and maintenance of these respective networks, and the push to move road...
Real Economy Year Book 2014 (PDF Report)
This edition drills down into the performance and outlook for a variety of sectors, including automotive, construction, electricity, transport, steel, water, coal, gold, iron-ore and platinum.
Real Economy Insight: Automotive 2014 (PDF Report)
This four-page brief covers key developments in the automotive industry over the past 12 months, including an overview of South Africa’s automotive market, trade figures, production and the policies influencing the sector.
 
 
 
 
 
This Week's Magazine
South Africa remains an important manufacturing and export platform for Ford Motor Company, says executive chairperson Bill Ford. However, he adds that other countries on the continent are “becoming interesting”, and that the US carmaker is casting its net wider for...
TO BE PHASED INTO SERVICE The first MeerKAT dish, with another 63 to come
Germany’s Max-Planck-Society (MPG) and the Max-Planck-Institute for Radio Astronomy (MPlfR) are investing €11-million (about R150-million) into South Africa’s MeerKAT radio telescope array programme. The money will be used to design, build and install S-band radio...
Infrastructure spend in sub-Saharan Africa will grow from $70-billion in 2013 to $180-billion by 2025, says PwC capital projects and infrastructure Africa leader Jonathan Cawood. This is one of the findings of PwC’s Capital Projects & Infrastructure report on East...
Private-owned defence and aerospace manufacturer Paramount Group and the Ichikowitz Family Foundation unveiled its Anti-Poaching Skills and K9 Training Academy in Magaliesburg last month.
MATT BARKER Wireless networks should enable users to engage and must provide relevant information to them based on their activity and location
The inclusion of Bluetooth to provide sub-three meter accuracy and heightened functionality for users is one of the ways to change existing wireless networks into engagement networks. An engagement network differs from common wireless networks in that it enables the...
 
 
 
 
 
 
 
 
 
Alert Close
Embed Code Close
content
Research Reports Close
Research Reports are a product of the
Research Channel Africa. Reports can be bought individually or you can gain full access to all reports as part of a Research Channel Africa subscription.
Find Out More Buy Report
 
 
Close
Engineering News
Completely Re-Engineered
Experience it now. Click here
*website to launch in a few weeks