Improving Mean Time to Repair in High Head pumps
May 6, 2021
High head pumps are the workhorses of many industrial fluid control systems. Their role can often be mission-critical,...
Sustainability is increasingly becoming a crucial requirement for operators and end-users as regulations have become more demanding and stricter. To operate in a more sustainable and environmentally friendly way, operators are reviewing all their equipment. One vital piece of equipment that can go a long way towards positively contributing to improved sustainability is dewatering pumps. Various factors should be considered, such as reducing downtime, improving serviceability, reducing emissions, legislation, and ensuring the pump is properly sized to operate most efficiently.
Decreasing downtime
Downtime is a significant contributor to sustainability. Reducing downtime means operators can work to maximum performance levels and improve operational efficiencies. There are two types of downtime: unplanned downtime, whereby a part fails, and the job needs to be stopped to repair the equipment, and predicted downtime that takes place for routine servicing and maintenance.
There are several ways downtime can be reduced. The first is to ensure the equipment is appropriate for the job at hand and robust enough to withstand the applications’ operating conditions; this will prevent premature failure. Also, ensure the equipment uses high-quality parts, it will work as expected and continue to run reliably with an optimum mean-time-to-repair (MTTR).
WEDA range innovative hydraulic design: the Wear Deflector Technology
Much development has been done to improve pump performance with specialized pump designs. For example, advanced pumps such as Atlas Copco’s PAC range have been designed to reduce downtime and prolong the lifespan. Therefore, reducing service OPEX. These models feature a closed impeller with innovative deflector vanes, enabling mechanical seals to last three times longer than comparable technologies.
In another example of pumps designed for maximum uptime, Atlas Copco’s WEDA range of electric submersible pumps has been built with a special Wear Deflector technology. Incorporated in the D70 variant initially, this innovative hydraulic design has resulted in an extremely durable pump that offers long-lasting performance under tough operating conditions. Solids suspended in water can cause an impeller to wear and prematurely fail. However, the unique Wear Deflector protects the hydraulic components of the pump from sand and other abrasive particles. The impellers are also manufactured from high-chrome stainless steel (55 HRC), having high hardness and unrivaled wear resistance.
Improving serviceability
Downtime associated with regular maintenance can be reduced by selecting equipment that has been designed to be easy to service. Features such as hinged doors offer quick and easy access to a pump’s internal workings for fast serviceability. Ease of maintenance can be further enhanced with designs features such as the semi-cartridge seal design on the PAS and PAC pumps allows seal access and replacement from the front without dismantling the pump.
Atlas Copco's PAS HardHat® self-priming pump
Indeed, the PAS HardHat® range incorporates these features and can be cleaned and restarted in just three minutes and serviced in under 60 minutes. The exclusive HardHat® polymer is resistant to corrosion and the effects of extreme temperatures and harsh operating environments, enabling increased durability on site.
Digital technologies, such as Atlas Copco’s FleetLink, can help improve monitoring and assist operators to work more efficiently. FleetLink enables remote monitoring of pump performance and condition, providing the operational insight needed to optimize pump usage and maintenance.
Increasing efficiency
Carbon footprint can be reduced by considering the energy source of the pumps as well as adhering to the European Stage V emissions regulations that specify a limit for particle number emissions from diesel engines.
Atlas Copco's WEDA D70 electric submersible pump
If electricity is available, an electric pump can be an efficient choice. Electric submersible pumps – such as the WEDA pumps – are the most energy-efficient, providing high power in light and compact packages. Atlas Copco has developed a handy sizing calculator for WEDA pumps. By simply entering some key technical information such as flow, static head, hose/pipe length, and diameter, the calculator provides operators with the most appropriate pump for their operation.
The PAC and PAS surface pump ranges are completely EU Stage V compliant. They are also certified to work with biodiesel Hydrotreated Vegetable Oil (HVO). This fossil-free fuel is the newest and cleanest generation of biodiesel, produced from recycled vegetable oils and fats. Additionally, PAS and PAC pumps feature an innovative electronic engine for more efficient operations.
Sizing for a sustainable future
The final way to improve efficiencies is by having the correct pump size. By using the right pump for the job, operators can remove water and sludge most effectively.
For the best value and efficiencies, consider the technical parameters and requirements. The pump selected should be able to handle the flow requirements with enough capacity to cope with fluctuations in water level as well as versatility to manage the demands of different sites. An oversized pump that can handle a much higher flow capacity than needed will be unnecessarily expensive; without providing the most cost-effective solution. On the other hand, a pump that has been under-specified will struggle to transport the media and wear out more quickly, resulting in a shorter life span.
Pumps are an essential piece of equipment on any site, and when considering the sustainability of a whole operation, they are a critical component to review. Working with trusted partners and manufacturers that can offer an extensive range of pumps designed to help operators reach their sustainability goals is key.
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Electric vs Diesel pumps
January 1, 2021
Equally, it is a decision that applies to the choice of dewatering pump technologies for operations within the construction, mining, utilities and municipal arenas.
However, unlike the automotive debate, it is not a contest of technical...
