Increase Your Submersible Pump Efficiency
Most facilities depend on Submersible pumps/pumps to perform effectively and produce their intended products with the expected system reliability.
Grand View Research breaks down the global industrial market share for 2020 into five significant categories: construction, chemicals, oil and gas, water and wastewater, and power.
The need for chemical products from manufacturing, the automotive industry, and construction is continuously increasing globally.
In order to keep up with the increased demand for power and energy that comes along with ongoing population growth, industries and municipalities must use more different Submersible pumps/pumps.
To gain or keep a competitive advantage, users must maintain Submersible pump/pumps at the plant level with effective and efficient preventative maintenance (PM).
Numerous potential problems must be examined. A few examples include excessive vibration or noise, shaky mounting points, high or low bearing temperatures, leaky gaskets, and Submersible pump/pump flanges, and weak electrical connections.
Most Submersible pump/pump failures are caused by corrosion, cavitation, wear, etc., and begin long before they are noticed. The biggest problem, still today, is probably a human mistake.
A lack of resources, incorrect maintenance frequencies, precision maintenance training, and a lack of utilization of condition-based monitoring and predictive technology cause this.
Because adopting a proactive maintenance mindset is a difficult shift process, many businesses are still having trouble. Some people are trying to improve their maintenance skills.
Instead, they ought to adopt a reliability-based strategy and concentrate more on the need for maintenance in the first place. Beyond the asset’s intrinsic reliability, users are unable to maintain it.
Others are working on reliability-centered maintenance (RCM), which makes decisions taking into account a user’s restricted resources and business environment.
Following are the mistakes to avoid to improve the efficiency of your submersible pump/pump system:
1. Don't Oversize the Submersible pump/pump
When engineers define a Submersible pump/pump, they frequently include a margin of safety in terms of the given pump’s duty in comparison to what the application calls for.
It is commonly known that centrifugal Submersible pump/pumps, which make up around 80% of all installed pumps, are frequently oversized by 20% to 30%.
An oversized Submersible pump/pump may use more energy than necessary since increased flow and pressure performance demands more power from the motor.
While choosing a Submersible pump that will operate as close to its Best Efficiency Point as is practical can greatly minimize energy usage, some oversizing may be prudent to account for design process uncertainties.
2. Not Trimming the impeller
Trimming the impeller is a somewhat cost-effective approach to reduce the pressure and flow produced by an oversized Submersible pump/pump.
As an impeller is shrunk, the clearances between it and the casing are bigger, making it less efficient than a full-sized impeller, even though trimming the impeller is far more energy efficient than employing a throttling valve to achieve the needed duty.
Because of this, variable-speed drives are frequently the best option in terms of the energy economy.
3. Not using Drives with variable frequency
Variable frequency drives, as their name implies, adjust the motor’s rotational speed to meet the application’s real head and flow requirements rather than the Submersible pump/pump’s capacity.
In two situations, VFDs are frequently employed to reduce needless energy use. At first, they slow the motor of a Submersible pump/pump that was designed with an enormous motor.
The second application for a VFD is when the duty demands on the Submersible pump/pump change over time.
When this is the case, the Submersible pump/pump must be able to function at maximum capacity when necessary yet may do so for extended periods of time at a lower capacity.
A cooling Submersible pump/pump is an example of this when the temperature of the equipment or fluid that has to be cooled may vary greatly.VSDs do have a cost, however, in most cases, the money saved on energy costs makes up for it.
4. Neglecting the Instruction and Operating Manual (IOM)
Failure to read or follow IOM instructions is the most frequent Submersible pump/pumping mistake made by users.
An IOM is a document produced by a pump manufacturer that provides accurate instructions for the setup, use, and upkeep of the Submersible pump/pumping system.
Following the pump manufacturer’s instructions strictly is essential. If you don’t do this, the Submersible pump/pump’s performance and durability can suffer, and the manufacturer’s guarantee will no longer be valid.
The majority of IOM manuals are designed to include outline drawings, Submersible pump/pump test data, sources for replacement components, cross-sectional assembly drawings, and authorized services in addition to the usual instructions. So, whatever issue may happen, IOM will have the solution.
5. Starting Submersible pump/pumps without Oil in the Bearings
If you are starting a Submersible pump/pump without oil in the bearing, we ask that you kindly refrain from doing so. Early degradation and excessive wear in the Submersible pump/pumps could result in some damage.
The water Submersible pump/pumps may develop a number of serious problems, including unusual noises made during the operation, misalignment, temperature rise brought on by friction, corrosion, discoloration, and cracks.
6. Using it unnecessarily
Despite the fact that this appears straightforward, it’s astonishing how frequently Submersible pump/pumps are used inefficiently.
Standby Submersible pump/pumps can be turned off using control systems, and pressure switches can be used to regulate the number of Submersible pump/pumps operating when duty demands change.
This can ensure that just one Submersible pump/pump is required to operate under the current system circumstances, preventing the use of several Submersible pumps/pumps at once.
7. Operating the Second Submersible pump/pump in Parallel to Boost Flow
Installing numerous pumps to offer flexibility in the flow rates that must be delivered is an alternative to using VSDs for a system with a wide variety of workload needs.
The system has greater operational flexibility, increased efficiency, and the ability to continue running in the case of a Submersible pump/pump failure when multiple Submersible pumps/pumps are used as opposed to just one. It also requires less maintenance.
One of the standard setups for this system is to mount a small Submersible pump/pump to control low flow rates and a large Submersible pump/pump to handle the maximum intended flow. It ensures that no Submersible pump/pump needs to operate too far from its BEP (Best Efficiency Point).
But choosing a suitable Submersible pump/pump is crucial to achieving these benefits because improper Submersible pump/pump selection for parallel Submersible pump/pumping or improper pump operation will negate these benefits. The system’s dependability and overall effectiveness could thus be jeopardized.
8. Not Executing timely maintenance
As with any piece of equipment, routine maintenance can help your Submersible pump/pump operate more efficiently and reduce energy usage.
Submersible pump/pump maintenance, which includes replacing eroded wear rings, is essential because increased wear ring clearance causes leakage, which raises the power needs of the Submersible pump/pump to provide the same flow.
Before it is replaced, a pump’s energy efficiency can decrease by up to 10–25%. The greatest approach to lower your Submersible pump/pump’s long-term energy expenditures at this point is to improve it!
Epoch Automation is the leading producer and exporter of submersible pumps of the highest caliber. Our submersible pumps are extremely durable and don’t need frequent maintenance or repairs because they are created using cutting-edge technology. All of our items have extended warranties so you won’t have to buy new ones as frequently.
Try Epoch Automation’s products if you want to receive a return on your investment for your pumps because we have pumps for practically every need, including residential, industrial, agricultural, etc. Get more details about our premium pumps and motors by getting in touch with us.