http://www.engineeringnews.co.za
  SEARCH
Login
R/€ = 13.13Change: -0.02
R/$ = 12.07Change: -0.13
Au 1187.17 $/ozChange: -20.08
Pt 1125.50 $/ozChange: -23.50
 
 
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 Letters Contact Us
 
 
 
RSS Feed
Article   Comments   Other News   Research   Magazine  
 
 
Feb 27, 2013

Company Announcement: The benefits of pump system optimisation

Back
Flow|Health|PROJECT|Pumps|SKF|SKF Energy Monitoring Service - Pump Systems|System|Systems|Training|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|Health|PROJECT|Pumps|SKF|System|Systems|Training|Energy|Equipment|Flow|Maintenance|Service|Services|Systems||Power|Bearings|Operations
flow-company|health|project|pumps|skf|skf-energy-monitoring-service---pump-systems|system|systems-company|training|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
Updated 3 hours ago The pioneering oil-free and direct-drive technology built into the oil-free LZ piston compressor range from Atlas Copco Compressor Technique ensures the efficient and reliable delivery of absolutely 100% clean air. “Piston compressors have always presented a...
Updated 3 hours ago Epicor Software Corporation, a global leader in business software solutions for manufacturing, distribution, retail and services organizations, today announced that a successful implementation of the Epicor Prophet 21 wholesale distribution enterprise resource...
Updated 4 hours ago South African Airways the leading carrier on the African continent, has - in what is a significant achievement for the airline – strengthened its position in West Africa, with the upcoming introduction of a second West African country linking air travel to North...
More
 
 
Latest News
Updated 2 hours 26 minutes ago JSE-listed Dipula Income Fund reported that its distributable earnings grew 33.2% in the six months ended February 28, translating into a combined growth of 6.8% in distributions for both A- and B-linked units. The distribution attributable to the A-linked units was...
Updated 2 hours 33 minutes ago JSE-listed Growthpoint Properties’ Kirstenhof Office Park, in Johannesburg, has become the hundredth building in South Africa to achieve a Green Star SA certification from the Green Building Council of South Africa (GBCSA), securing a 5-Star Green Star: Existing...
NASREC MEMORIAL PARK
Updated 2 hours 48 minutes ago JSE-listed residential property developer Calgro M3 Holdings’ subsidiary, Calgro M3 Memorial Parks has diversified its portfolio by officially launching its first memorial park, in Nasrec, near Soweto. This is the first development of its kind by Calgro M3 in what it...
More
 
 
Recent Research Reports
Steel 2015: A review of South Africa's steel sector (PDF Report)
Creamer Media’s Steel 2015 report provides an overview of the key developments in the global steel industry and particularly of South Africa’s steel sector over the past year, including details of production and consumption, as well as the country's primary carbon...
Projects in Progress 2015 - First Edition (PDF Report)
In fact, this edition of Creamer Media’s Projects in Progress 2015 supplement tracks developments taking place under the Renewable Energy Independent Power Producer Procurement Programme, which has had four bidding rounds. It appears to remain a shining light on the...
Electricity 2015: A review of South Africa's electricity sector (PDF Report)
Creamer Media’s Electricity 2015 report provides an overview of State-owned power utility Eskom and independent power producers, as well as electricity planning, transmission, distribution and the theft thereof, besides other issues.
Construction 2015: A review of South Africa’s construction sector (PDF Report)
Creamer Media’s Construction 2015 Report examines South Africa’s construction industry over the past 12 months. The report provides insight into the business environment; the key participants in the sector; local construction demand; geographic diversification;...
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.
 
 
 
 
 
This Week's Magazine
While economic forecasts for the African continent are most favourable, African airlines may not be able to benefit from the expected growth in the region’s gross domestic product (GDP), International Air Transport Association VP: Africa Raphael Kuuchi has warned....
The Automotive Production and Development Programme (APDP) will need to change substantially post 2020, says Metair Investments South African operations COO Ken Lello. “We must not make tweaks. We have to change. What we are doing is not sustainable.”
Banking group Absa’s forecast is for the rand to end the year at around R13 against the dollar, weakening further to R13.50 by 2016, says Absa sectoral analyst Jacques du Toit. He warns that possible interest rate hikes in the US may see capital being pulled from...
The Dispute Resolution Centre at the Bargaining Council for the Civil Engineering Industry (BCCEI) is now open to handle party-to-party disputes. The BCCEI represents the interests of all level four to nine Construction Industry Development Board companies.
FREDRIK JEJDLING Sustainability becomes an important part of a business’ decision-making process
Communications technology firm Ericsson sub-Saharan Africa head Fredrik Jejdling says the company’s commitment to sustainability and corporate responsibility has been integrated into all facets of its operations, which has provided it with sustainable revenue...
 
 
 
 
 
 
 
 
 
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
Subscribe Now for $96 Close
Subscribe Now for $96