When you want to save on energy costs, pumps might not be your first thought. But think again. Pumps actually consume around 10 % of the world's energy, less than any other type of equipment.

And while pump optimization is not a new idea, the drive to reduce CO2 emissions and operating costs gives it ever greater relevance. As well as comparing purchase price, it is also important to compare energy consumption over a lifecycle. Considering pump sizing at an early stage in plant design is a must.

How to deal with unreasonable process pump design and non-optimal operation? The process pump expert gave the following recommendations.

1. Organization and management level
Retain the rich experience inside the company, set up the process pump management department, each process equipment operator should have a certain level of process pump technical expertise. Even if the technical service company outside the operator undertakes most of the work related to the process pump, the field operator of the process equipment operator should have certain expertise, such as proposing reasonable suggestions for improving daily operations.
In addition, companies need to always plan and design their process pumps and process equipment systems as a whole. If the partner in the process design stage of the process pump does not have a little knowledge of process pump technology, the design results will not be optimal.

2. Participate in the forum of professional and technical knowledge exchange

It is very necessary to exchange experiences at relevant meetings. It is different from daily work every day. It is very beneficial to contact some peers with similar experiences and problems and keep in touch and exchange experiences. The management of the process equipment operator company should be aware that the employees attending such meetings will return to your business with a low-cost solution. You must have a small amount of money in your hands to save a lot of money when planning, designing, installing, and commissioning process pumps.

3. Make full use of the training opportunities provided by the manufacturer
In principle, technical training provided by process pump manufacturers is a good time to learn new technologies and new knowledge, and companies should make full use of these training opportunities. Since the knowledge of process pump technology in many operators is not concentrated in one department, it is one of the reasons for not receiving good results. If a single operation engineer participates in such technical training, the training effect is weakened.

4. Maintenance is the value of maintenance
Practice has shown that in recent years, especially in large industrial enterprises, the concept of maintenance has undergone fundamental changes. Maintenance personnel are continually decreasing, and the loss of technical expertise leads to poor schedule maintenance of process pumps or the inability to implement maintenance plans. The result is usually not a reduction in expected costs, but an increase in maintenance costs and the loss of unplanned process pump lockout failure. Therefore, the manager of the enterprise should not regard maintenance as a cost library that consumes resources and expenses, but should be understood as a measure of preservation of asset value preservation.

5. Avoid assembly errors and suppress vibration
The operator may start making mistakes during the assembly process, such as twisting the pipe to the process pump, which will cause the process pump body to warp and the bearing clearance to be incorrect, which will quickly assemble the process pump. Workers and pipe fitters are overwhelmed.
Under unfavorable operating conditions, each system generates a strong resonance through the natural frequency and is destroyed in a short period of time, such as bearings. Process pumps operating in series are more intense due to the similar speed, and an effective solution is to choose a larger speed difference. Installing a vibration sensor is also a good remedy.

6. Using the monitoring system
It is more important for qualified employees to look, listen and smell at the process of the pump work than any other electronic monitoring. You don't have to pay attention to the latest technical development announcement. The tried and tested technology has been very useful for many years, using IDM sound control and variable speed drives to ensure that the operation is flawless. In addition, in the digital age, you must also learn how to correctly interpret the generated data. This requires a deep understanding of process pump technology, and it means that we are back to the topic of know-how. Monitoring technology is not a panacea. If the design or installation of the process pump is wrong, even the best monitoring technology can only play a limited role.

7. Using speed adjustment
When companies are aware of deficiencies in the organization and technology, and are unable to take effective remedies in the short term, there are other ways to reduce process pump problems, such as adjusting the speed of the process pump drive motor. This greatly increases the flexibility of the process pump operation and also calibrates the operating point of the process pump at any time. Of course, the cost of this flexibility is also relatively high (electrical control cabinets, frequency converters, shielding, etc. are often the same as a process pump). In addition, the energy efficiency of this formulation is not optimal.

8. Preventive maintenance is an opportunity
Pattern recognition with big data and intelligent data and artificial intelligence is an important tool in preventive maintenance. But it must be noted that there is not much distance between people and technology, especially in the analysis of data. In general, the benefits of preventive maintenance are overestimated, and most mechanical equipment failures stem from factors that preventive maintenance cannot solve, the most obvious of which is operator error.

9. Use the potential of standardization
Why is standardization so important? On the one hand, there are fewer and fewer people who know the various pump systems at the production site. If standardization is achieved, some operational problems can be solved. On the other hand, the number of inventory parts is less and less.
Another advantage of standardization is operation. A framework agreement can be signed with the manufacturer, and it is sufficient to call the type of process pump specified in the supply agreement when needed.

10. Positive displacement pump

When the viscosity of the pumped media starts to increase, consider a positive displacement pump, which may use significantly less power as viscosity rises. Bonve Rotary lobe pump is self-priming, valveless, positive displacement pumps. With the characteristics of low rotation speed and high output torque, pump shows his talents to transfer high viscosity liquid products. Its unique working principle works with a strong drive system, ensure that the pump can output a strong driving torque at low speed, can guarantee continuous, non-stagnant transferring, and ensure that the transferred material not damage, viscosity can be as high as 1500000CP. More details click picture to get more.

Cutting energy costs is not just about buying a high-quality pump. It's about selecting the right pump for each application. Contact us with your application.