Feb 27, 2013
Company Announcement: The benefits of pump system optimisationBack
Bearings|Energy|Flow|Paper|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|Flow|Machinery Breakdowns|Systems|Wasted Energy|Power|Bearings
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.
Edited by: Creamer Media ReporterComment Guidelines
Other Announcements News
Steve Burks has been appointed as an Associate Director of Johannesburg-based MAC Consulting, a broad-based management consulting group focused on mining, oil and gas, financial services, and telecommunications. Mr Burks previously ran the African operations of...
Leading South African black-owned consulting engineering firm, GIBB, clinched the number one spot for the second time in the Consulting Engineers Sector category of the Annual Top 500 company survey. The last time GIBB secured the same award was in 2012. Topco Media...
South Africa's most switched-on brands are now able to engage with customers on the world's most powerful social media platform following news that Resolve Mobile is an approved WeChat official accounts integration and support partner. Resolve Mobile is the mobile...
Updated 7 minutes ago World Trade Organisation (WTO) director-general Roberto Azevêdo assured the organisation’s General Council on Thursday that trade will continue to be a focus in the post-2015 Development Agenda, with a primary goal being the achievement of a “significant”...
Updated 23 minutes ago Global revenues from solar energy operations could double from $59.84-billion in 2013 to $137-billion in 2020, new analysis from Frost & Sullivan shows. The consultancy’s ‘Global Solar Power Market’ report says the total global installed solar photovoltaic (PV)...
Updated 38 minutes ago The biennial Sasol Solar Challenge will kick off on September 27, in Pretoria, and end in Cape Town, on October 4. Fourteen teams will take part, of which eight are local, says race project manager Annalie van Vuuren.
Recent Research Reports
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.
Real Economy Insight: Construction 2014 (PDF Report)
This five-page brief covers key developments in the construction industry over the past 12 months. It provides an overview of the sector and includes details of employment in the sector, infrastructure and municipal spending, as well as insight into companies’...
Real Economy Insight: Electricity 2014 (PDF Report)
This five-page brief covers key developments in the electricity industry over the past 12 months, including details of State-owned power utility Eskom’s generation activities, funding and tariffs, independent power producers and prospects for the sector.
Real Economy Insight: Road and Rail 2014 (PDF Report)
This six-page brief covers key developments in the road and rail industries over the past 12 months, including details of South Africa’s road and rail network and prospects for both sectors.
Real Economy Insight: Steel 2014 (PDF Report)
This four-page brief covers key developments in the steel industry over the past 12 months. It provides an overview of the global and South African steel and stainless steel markets, South Africa’s major steel producers and events that have shaped these markets.
This Week's Magazine
Multinational semiconductor chipmaker corporation Intel announced its national campaign to further acquire partners to drive its She Will Connect programme, an initiative that aims to expand digital literacy skills to young women in developing countries, further into...
South Africa's MeerKAT radio telescope array programme should get back on schedule within a few months. This assurance has been given by SKA South Africa (SKA SA) associate director: science and technology Prof Justin Jonas. Early last month, Science and Technology...
The Passenger Rail Agency of South Africa’s (PRASA’s) Metrorail service will remain a subsidised service following its current multibillion-rand rolling stock, station, depot and signalling upgrade programme. PRASA group CEO Lucky Montana has allayed fears that...
The uncertainties around the remediation of affected areas as addressed in the Contaminated Land Provisions in the National Environmental Management: Waste Act No 59 of 2008 will possibly spark litigation and disputes between landowners and businesses, contractors...
South Africa is currently the largest component of the African Development Bank’s (AfDB’s) active portfolio in Southern Africa, comprising 62.5% of the bank’s $7.9-billion exposure to the 12-country region – the second largest beneficiary is Mauritius, which...