Pump Systems Academy

Pump vibration analysis is a crucial aspect of effective maintenance for industrial pumps. Vibrations can indicate wear and tear, alignment issues, and other potential problems that, if left untreated, can lead to costly downtime and repairs. As plant engineers and pump maintenance technicians, it's essential to understand the importance of pump vibration analysis and how it can help you identify and address issues before they become major problems. In this article,...

As an industrial plant operator, you know that noisy water pumps can cause a whole host of problems. From disrupting the work environment to indicating potential malfunctions, it's essential to address any loud pump noises as soon as possible. But how do you go about quieting these essential machines? In this article, we'll share our expert tips for reducing pump noise and ensuring your plant runs as smoothly as possible.

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As a result of conservative engineering practices, pumps are often substantially larger than they need to be for an industrial plant’s process requirements. Centrifugal pumps can often be oversized because of  “rounding up,” trying to accommodate gradual increases in pipe surface roughness and flow resistance over time, or anticipating future plant capacity expansions. In addition, the plant’s pumping requirements might not...

A pump’s efficiency can degrade as much as 10% to 25% before it is replaced, according to a study of industrial facilities commissioned by the U.S. Department of Energy (DOE), and efficiencies of 50% to 60% or lower are quite common. However, because these inefficiencies are not readily apparent, opportunities to save energy by repairing or replacing components and optimizing systems are often overlooked.

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Overview 

Centrifugal pumps handle high flow rates, provide smooth, non pulsating delivery, and regulate the flow rate over a wide range without damaging the pump. Centrifugal pumps have few moving parts, and the wear caused by normal operation is minimal. They are also compact and easily disassembled for maintenance. The design of an efficient pumping system depends on relationships between fluid flow rate,...

Every industrial facility has a piping network that carries water or other fluids. According to the U.S. Department of Energy (DOE), 16% of a typical facility’s electricity costs are for its pumping systems. 

The power consumed to overcome the static head in a pumping system varies linearly with flow, and very little can be done to reduce the static component of the system requirement. However, there are several energy- and money-saving opportunities t...

Understanding Your Pumping System Requirements 

Pumps transfer liquids from one point to another by converting mechanical energy from a rotating impeller into pressure energy (head). The pressure applied to the liquid forces the fluid to flow at the required rate and to overcome friction (or head) losses in piping, valves, fittings, and process equipment. The pumping system designer must consider fluid properties,...

When multiple pumps operate continuously as part of a parallel pumping system, there can be opportunities for significant energy savings. For example, lead and spare (or lag) pumps are frequently operated together when a single pump could meet process flow rate requirements. This can result from a common misconception—that operating two identical pumps in parallel doubles the flow rate. Although parallel operation does increase the flow rate, it also causes greater fl...

An industrial facility can reduce the energy costs associated with its pumping systems, and save both energy and money, in many ways. They include reducing the pumping system flow rate, lowering the operating pressure, operating the system for a shorter period of time each day, and, perhaps most important, improving the system’s overall efficiency.

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Effective pump maintenance allows industrial plants to keep pumps operating well, to detect problems in time to schedule repairs, and to avoid early pump failures. Regular maintenance also reveals deteriorations in efficiency and capacity, which can occur long before a pump fails. Wear ring and rotor erosions, for example, can be costly problems that reduce wire-to-water efficiency by 10% or more. 

The amount of attention given to maintenance depends on how important a system is to...

Pumping system control valve inefficiencies in plant processes offer opportunities for energy savings and reduced maintenance costs. Valves that consume a large fraction of the total pressure drop for the system or are excessively throttled can be opportunities for energy savings. Pressure drops or head losses in liquid pumping systems increase the energy requirements of these systems. Pressure drops are caused by resistance or friction in piping and in bends, elbows, or joints, as well as by t...

In pumping applications with variable flow rate requirements, adjustable speed drives (ASDs) are an efficient control alternative to throttling or bypass methods. ASDs save energy by varying the pump’s rotational speed. In centrifugal pumping applications with no static lift, power requirements vary...

In the United States, more than 2.4 million pumps, which consume more than 142 billion kWh annually, are used in industrial manufacturing processes. At an electricity cost of 5 cents per kWh, energy used for fluids transport costs more than $7.1 billion per year. Even one pump can consume substantial energy. A continuously operated centrifugal pump driven by a fully loaded 100-horsepower motor requires 726,000 kWh per year....

Let's talk about centrifugal pump impellers. These little guys are the backbone of any pumping system, and it's important to keep them happy if you want your system to run smoothly. Unfortunately, one of the biggest culprits of energy waste and lost efficiency is impeller clearance. But don't worry, as a mechanical engineer, you've got the skills to tackle this problem head-on. In this guide, we'll show you how to keep those impellers in top shape and make sure...

Hey there! As mechanical engineers, we know that the performance of centrifugal pumps is crucial for many industries. At Dynapro Pumps, we're passionate about promoting sustainable industries by reducing energy, water, and wear parts consumption in pumping systems. That's why we're excited to introduce you to the Pump Systems Academy, where we share our expertise on everything related to mining and industrial pump systems. In this blog post, we'll be giving mechanical...

As engineers, you know how important pumps are for industrial processes to run efficiently. However, when cavitation rears its ugly head, it can quickly undermine even the most advanced pump systems. Cavitation can cause damage to pump components, reduce efficiency, and increase downtime, resulting in significant losses for your company and headaches for you.

At the Pump Systems Academy, we've seen how challenging cavitation...

Welcome to the Pump Systems Academy, the leading source for solving all issues related to mining and industrial pump systems. Here, we strive to accelerate the transition to sustainable industries through the reduction of energy, water, and wear parts in pumping systems. As plant managers and mechanical engineers, you understand the crucial role that pumps play in industrial applications. That's why we are proud to present this comprehensive guide on the Affinity...

When exploring and learning about pumping systems, I was amazed at the information available online today in 2021.  For a non-engineer, there are numerous sites that provide incredibly easy to read and understand information.  The U.S. department of energy has done an excellent job with their tear sheets.  I’ve provided the information that they teach, as it’s an incredibly reliable resource:

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