I. Overview
Pump power loss and pump maintenance have long been two major problems surrounding users. Power loss leads to increased costs, and maintenance of the pump during operation is always a headache for the user. There is no doubt that technological changes around the two areas of pump efficiency and pump maintenance costs have become the driving force behind pump technology. Through the analysis of the recent development of pump technology, this paper reveals the technical characteristics of improving pump efficiency, the reasons why variable frequency drive, intelligent pump and pump system are widely used. The role of applied electronic components and the efforts of European and American pump standards are introduced.
Second, improve the development of pump efficiency technology
In 1995, Europharm and the European Pump Manufacturing Industry Association established an energy-saving project and began to focus on energy-saving research. At the same time, the American Society of Hydraulics (HI), the American Pump Industry Trade Association, assisted the US Department of Energy in preparing a video on energy savings in pumps and pump systems.
In the future, HI formed the Life Cycle Cost (LCC) Committee for Pump Products, which aims to educate pump users, manufacturers and engineers on the life cycle cost concept of pumps and pump systems. For most pumps, one of the most important factors in LCC is power loss, so the LCC study was developed to be a project that is compatible with the European pump's energy efficiency.
Against the background, pump manufacturers around the world are re-engineered to improve pump efficiency in design and reduce pump power loss during operation. It is worth noting that the pump is already a mature product, so the possibility of simply improving pump efficiency is small. However, research in this area of ​​improving pump efficiency losses is very promising. Some manufacturers use non-metallic materials or carbon on aerospace to seal the gaps in pump operation, improving pump efficiency. For example, the gap between the pump impeller and the inner ring of the pump casing, the gap between the intermediate bushings, and the like.
Some countries are quietly conducting research and trying to improve the quality of the surface of the runner inside the pump. The smoother the surface of the housing, the lower the water resistance. Thereby increasing the efficiency of the pump.
Composite materials are comparable to many metals, and they can be machined to produce a smooth surface. The blades of the impeller are machined into different geometries and assembled onto the impeller. Thus, the design engineer can ignore the roughness of the pump casing surface, the core shift or other casting problems. Composite materials can be used in place of copper-tin alloy (bronze) and 316 stainless steel for brine or corrosive fluids.
However, in non-wearing, non-corrosive fluids, such as clean water, composites do not have the advantage of competing with cast steel materials.
Third, variable frequency drive
In most countries, variable frequency drives (VFDs) are used more often for applications requiring precise flow control, variable speed or long-running large pumps with high power losses.
1. Application field
(1) The commercial construction industry matches the VFD in the air conditioning system for closed-loop pumping of cooling water in high-rise buildings.
(2) Pipeline industry In order to save energy in the pump and pipe industry, many countries use VFD. In the pipeline industry, a large number of large pumps (up to 10,000 brake horsepower) are used, so the amount of VFD is also very large.
(3) Centrifugal pump The centrifugal pump adopts the movable shaft design, which will cause the first critical speed to be higher than the maximum working speed; it will also cause the reduced VFD output speed to approach other critical speeds of the pump. But sometimes there are uncertain vibration problems, but the problem will be solved.
(4) In addition, a large number of VFDs are used in the electrical, food processing, water and wastewater treatment industries; small quantities of VFDs are used in the pharmaceutical, chemical and refining industries. Although pumps are not the core equipment in these areas, they play a vital role. These industries use more small pumps than large pumps, and they can use a regulating valve to control flow without using a variable-speed, energy-saving small pump.
2. main feature
(1) Energy saving A large number of VFDs are used in the water treatment and sewage treatment industries. When the pump system is to change the flow output, using VFD can save energy by switching off and starting a separate pump to change the flow output.
(2) Convenience When there is a small amount of flow, a single pump shutdown and starting method requires a large number of pumps, while using the variable speed pump method requires only a certain number of pumps and avoids water hammer when the pump is turned off.
(3) Special functions VFD can be used in food processing to achieve a variety of fluid participation or process control.
In the electrical industry, VFD is used to regulate the speed of boiler feed pumps. The load is reduced and the steam is reduced. The drive of the motor or main turbine generator shaft can be used to adjust the speed of the boiler feed pump to match the needs of the system and the energy saving requirements. Sometimes, the separated steam turbine is used to drive the boiler feed water pump and change the pump's speed and flow output.
3. Other features
VFD can replace flow control valves and monitoring instruments for precise flow control. The VFD controls the change in pump speed to achieve control of pump output pressure or output flow.
The VFD can make the pump start smoothly, avoiding the sudden increase of the flow rate when the pump starts to start at full speed, causing water hammer. At the same time, reducing the impact of fluid and mechanical pressure reduces the fatigue of the system, saves the cost of the motor, and increases the life of the pump.
4. new development
In recent years, the use of VFDs as components in volumetric pumps in powertrain systems has become very common. Its function is equivalent to a process controller controlling the output of the volumetric pump.
Fourth, the intelligent pump
The intelligent pump is a new product, and its concept varies from person to person. The intelligent pump we refer to refers to the use of instrumentation testing equipment to feedback the on-site signal to the intelligent pump analysis system. After analysis, judgment, analysis system gives the pump when And how to create a fault.
Because the monitoring equipment is closely related to the operation of the pump, it is critical for the user of the pump to monitor the equipment. The pump manager needs to know what the Mean Time Between Failure (MTBF) is for a given pump operation in order to schedule an overhaul interval (MTBO) to repair and replace worn and worn parts in a timely manner.
HI has written a related literature that lists 14 ways to monitor a centrifugal pump. They are power, temperature, corrosion, leak detection, pressure, vibration, lubrication analysis, shaft conditions, pre-installation hydraulic testing and design review. Effective monitoring of each method prevents and detects pump failures.
Since the inspection equipment and the intelligent pump analysis equipment are very expensive, the overall development of the smart pump is slow. In general, monitoring equipment is used in very large pumps and in very important processes.
Several pump manufacturers around the world offer intelligent pumping equipment for boiler feedwater pump control in the electrical industry. There is no steam cycle without a boiler feed pump. For example, a 500 MW, 2400 PSI power plant requires two 12,000 hp feed pumps. It is very important to monitor the operation of the pump.
The pipeline industry requires smart pumping equipment to control oversized pumps and very important processes. Suppliers of decarbonization and descaling pumps and multistage pumps are equipped with intelligent pumps for refineries for the same reason.
The existing intelligent pump system can help users extend the pump failure interval, and fault analysis can help determine the cost of maintenance. Of course, as smart pumps become more widely used, their prices will fall.
Fifth, electronic applications
In recent years, electronic technology has played a key role in the development and transformation of science and technology. In the pump and pump systems, electronic technology is becoming more widely used. The detection of the pump and the diagnostic system of the pump and the communication between the two require electronic technology. Without electronic components, the use of variable frequency drive pumps in conjunction with system equipment or energy savings is simply not possible.
The high pressure pump lubrication system is a very complex system that uses a wide variety of electronic equipment to perform accurate operations.
The boiler feed water pump needs to be preheated before starting, the heat flow flows evenly, and the rotor of the pump can rotate normally. Electronic components are used in the control system to ensure safe operation of large pumps.
The proportioning pump and metering pump use electronic technology to complete the fluid integration process to achieve the desired results. For example, in drinking water, chlorine and gas are not completely independent. They require electronic components. Without electronic components, the entire system cannot be completed.
In short, the pump industry's reliance on electronics is becoming more serious. Pump manufacturers need the ability to independently manufacture complete pump systems, and each subsystem requires electronic components.
Sixth, the pump system
In the Middle East, parts of the Far East, Africa and Latin America, water treatment and wastewater treatment projects require pump manufacturers to manufacture a complete pump package. This includes pipes, valves, start-up and measuring equipment. In some areas, such as Venezuela, even pump suppliers are required to work on construction and municipal facilities.
Pump users around the world want the pump supplier to complete all subsystems to ensure safe and smooth operation of the pump system. Subsystems include monitoring systems, shift control, flow or program control, preheating systems, lubrication control, and more. The trend in the world is that users prefer to buy the entire pump system instead of just one pump.
The purpose of the user's purchase of the pump system is to require the pump supplier to be fully responsible for the system and pumping. The user wants the pump supplier to warrant or repair the various subsystems of the pump, taking responsibility for the pump's own system and not just one pump.
In some developing countries, there is a shortage of engineers and technicians who assemble systems and test systems, so pump suppliers must send their own technicians to perform on-site operations, which is why pump systems are developing.
Now, suppliers can provide subsystems such as monitoring instruments, diagnostic equipment, electronic controls, preheat control and lubrication control systems. These subsystems are not only guaranteed by the pump manufacturer, but also designed and supplied by themselves, so that users are more assured when they purchase.
Once the pump has a problem in operation, the user only needs to find the pump supplier to solve the problem. Since the pump supplier is fully responsible for the pump system, it is appropriate for him to find out the problem and solve it.
Seven, the standard of the pump
Both Europe and the United States have a wide range of pump business associations.
The Pump Division, which has a large share of the market, has become the local representative of the Association. The association has built-in institutions that publish new standards or modify existing standards. There is the International Organization for Standardization (ISO) in Europe and the American National Standards Institute (ANSI) and the American Standards Association (ASA).
Europharm and HI reached an agreement to standardize the pump. In February 1996, the two organizations signed mutual cooperation agreements. The agreement stipulates that in order to benefit the mutual interests of both parties, the two organizations should enhance understanding and long-term cooperation, maintain the relationship between manufacturers and members of the association, technically communicate with pump users, share pump statistics worldwide, and build the Atlantic Ocean. Cross-strait and cross-border business contacts.
Pump power loss and pump maintenance have long been two major problems surrounding users. Power loss leads to increased costs, and maintenance of the pump during operation is always a headache for the user. There is no doubt that technological changes around the two areas of pump efficiency and pump maintenance costs have become the driving force behind pump technology. Through the analysis of the recent development of pump technology, this paper reveals the technical characteristics of improving pump efficiency, the reasons why variable frequency drive, intelligent pump and pump system are widely used. The role of applied electronic components and the efforts of European and American pump standards are introduced.
Second, improve the development of pump efficiency technology
In 1995, Europharm and the European Pump Manufacturing Industry Association established an energy-saving project and began to focus on energy-saving research. At the same time, the American Society of Hydraulics (HI), the American Pump Industry Trade Association, assisted the US Department of Energy in preparing a video on energy savings in pumps and pump systems.
In the future, HI formed the Life Cycle Cost (LCC) Committee for Pump Products, which aims to educate pump users, manufacturers and engineers on the life cycle cost concept of pumps and pump systems. For most pumps, one of the most important factors in LCC is power loss, so the LCC study was developed to be a project that is compatible with the European pump's energy efficiency.
Against the background, pump manufacturers around the world are re-engineered to improve pump efficiency in design and reduce pump power loss during operation. It is worth noting that the pump is already a mature product, so the possibility of simply improving pump efficiency is small. However, research in this area of ​​improving pump efficiency losses is very promising. Some manufacturers use non-metallic materials or carbon on aerospace to seal the gaps in pump operation, improving pump efficiency. For example, the gap between the pump impeller and the inner ring of the pump casing, the gap between the intermediate bushings, and the like.
Some countries are quietly conducting research and trying to improve the quality of the surface of the runner inside the pump. The smoother the surface of the housing, the lower the water resistance. Thereby increasing the efficiency of the pump.
Composite materials are comparable to many metals, and they can be machined to produce a smooth surface. The blades of the impeller are machined into different geometries and assembled onto the impeller. Thus, the design engineer can ignore the roughness of the pump casing surface, the core shift or other casting problems. Composite materials can be used in place of copper-tin alloy (bronze) and 316 stainless steel for brine or corrosive fluids.
However, in non-wearing, non-corrosive fluids, such as clean water, composites do not have the advantage of competing with cast steel materials.
Third, variable frequency drive
In most countries, variable frequency drives (VFDs) are used more often for applications requiring precise flow control, variable speed or long-running large pumps with high power losses.
1. Application field
(1) The commercial construction industry matches the VFD in the air conditioning system for closed-loop pumping of cooling water in high-rise buildings.
(2) Pipeline industry In order to save energy in the pump and pipe industry, many countries use VFD. In the pipeline industry, a large number of large pumps (up to 10,000 brake horsepower) are used, so the amount of VFD is also very large.
(3) Centrifugal pump The centrifugal pump adopts the movable shaft design, which will cause the first critical speed to be higher than the maximum working speed; it will also cause the reduced VFD output speed to approach other critical speeds of the pump. But sometimes there are uncertain vibration problems, but the problem will be solved.
(4) In addition, a large number of VFDs are used in the electrical, food processing, water and wastewater treatment industries; small quantities of VFDs are used in the pharmaceutical, chemical and refining industries. Although pumps are not the core equipment in these areas, they play a vital role. These industries use more small pumps than large pumps, and they can use a regulating valve to control flow without using a variable-speed, energy-saving small pump.
2. main feature
(1) Energy saving A large number of VFDs are used in the water treatment and sewage treatment industries. When the pump system is to change the flow output, using VFD can save energy by switching off and starting a separate pump to change the flow output.
(2) Convenience When there is a small amount of flow, a single pump shutdown and starting method requires a large number of pumps, while using the variable speed pump method requires only a certain number of pumps and avoids water hammer when the pump is turned off.
(3) Special functions VFD can be used in food processing to achieve a variety of fluid participation or process control.
In the electrical industry, VFD is used to regulate the speed of boiler feed pumps. The load is reduced and the steam is reduced. The drive of the motor or main turbine generator shaft can be used to adjust the speed of the boiler feed pump to match the needs of the system and the energy saving requirements. Sometimes, the separated steam turbine is used to drive the boiler feed water pump and change the pump's speed and flow output.
3. Other features
VFD can replace flow control valves and monitoring instruments for precise flow control. The VFD controls the change in pump speed to achieve control of pump output pressure or output flow.
The VFD can make the pump start smoothly, avoiding the sudden increase of the flow rate when the pump starts to start at full speed, causing water hammer. At the same time, reducing the impact of fluid and mechanical pressure reduces the fatigue of the system, saves the cost of the motor, and increases the life of the pump.
4. new development
In recent years, the use of VFDs as components in volumetric pumps in powertrain systems has become very common. Its function is equivalent to a process controller controlling the output of the volumetric pump.
Fourth, the intelligent pump
The intelligent pump is a new product, and its concept varies from person to person. The intelligent pump we refer to refers to the use of instrumentation testing equipment to feedback the on-site signal to the intelligent pump analysis system. After analysis, judgment, analysis system gives the pump when And how to create a fault.
Because the monitoring equipment is closely related to the operation of the pump, it is critical for the user of the pump to monitor the equipment. The pump manager needs to know what the Mean Time Between Failure (MTBF) is for a given pump operation in order to schedule an overhaul interval (MTBO) to repair and replace worn and worn parts in a timely manner.
HI has written a related literature that lists 14 ways to monitor a centrifugal pump. They are power, temperature, corrosion, leak detection, pressure, vibration, lubrication analysis, shaft conditions, pre-installation hydraulic testing and design review. Effective monitoring of each method prevents and detects pump failures.
Since the inspection equipment and the intelligent pump analysis equipment are very expensive, the overall development of the smart pump is slow. In general, monitoring equipment is used in very large pumps and in very important processes.
Several pump manufacturers around the world offer intelligent pumping equipment for boiler feedwater pump control in the electrical industry. There is no steam cycle without a boiler feed pump. For example, a 500 MW, 2400 PSI power plant requires two 12,000 hp feed pumps. It is very important to monitor the operation of the pump.
The pipeline industry requires smart pumping equipment to control oversized pumps and very important processes. Suppliers of decarbonization and descaling pumps and multistage pumps are equipped with intelligent pumps for refineries for the same reason.
The existing intelligent pump system can help users extend the pump failure interval, and fault analysis can help determine the cost of maintenance. Of course, as smart pumps become more widely used, their prices will fall.
Fifth, electronic applications
In recent years, electronic technology has played a key role in the development and transformation of science and technology. In the pump and pump systems, electronic technology is becoming more widely used. The detection of the pump and the diagnostic system of the pump and the communication between the two require electronic technology. Without electronic components, the use of variable frequency drive pumps in conjunction with system equipment or energy savings is simply not possible.
The high pressure pump lubrication system is a very complex system that uses a wide variety of electronic equipment to perform accurate operations.
The boiler feed water pump needs to be preheated before starting, the heat flow flows evenly, and the rotor of the pump can rotate normally. Electronic components are used in the control system to ensure safe operation of large pumps.
The proportioning pump and metering pump use electronic technology to complete the fluid integration process to achieve the desired results. For example, in drinking water, chlorine and gas are not completely independent. They require electronic components. Without electronic components, the entire system cannot be completed.
In short, the pump industry's reliance on electronics is becoming more serious. Pump manufacturers need the ability to independently manufacture complete pump systems, and each subsystem requires electronic components.
Sixth, the pump system
In the Middle East, parts of the Far East, Africa and Latin America, water treatment and wastewater treatment projects require pump manufacturers to manufacture a complete pump package. This includes pipes, valves, start-up and measuring equipment. In some areas, such as Venezuela, even pump suppliers are required to work on construction and municipal facilities.
Pump users around the world want the pump supplier to complete all subsystems to ensure safe and smooth operation of the pump system. Subsystems include monitoring systems, shift control, flow or program control, preheating systems, lubrication control, and more. The trend in the world is that users prefer to buy the entire pump system instead of just one pump.
The purpose of the user's purchase of the pump system is to require the pump supplier to be fully responsible for the system and pumping. The user wants the pump supplier to warrant or repair the various subsystems of the pump, taking responsibility for the pump's own system and not just one pump.
In some developing countries, there is a shortage of engineers and technicians who assemble systems and test systems, so pump suppliers must send their own technicians to perform on-site operations, which is why pump systems are developing.
Now, suppliers can provide subsystems such as monitoring instruments, diagnostic equipment, electronic controls, preheat control and lubrication control systems. These subsystems are not only guaranteed by the pump manufacturer, but also designed and supplied by themselves, so that users are more assured when they purchase.
Once the pump has a problem in operation, the user only needs to find the pump supplier to solve the problem. Since the pump supplier is fully responsible for the pump system, it is appropriate for him to find out the problem and solve it.
Seven, the standard of the pump
Both Europe and the United States have a wide range of pump business associations.
The Pump Division, which has a large share of the market, has become the local representative of the Association. The association has built-in institutions that publish new standards or modify existing standards. There is the International Organization for Standardization (ISO) in Europe and the American National Standards Institute (ANSI) and the American Standards Association (ASA).
Europharm and HI reached an agreement to standardize the pump. In February 1996, the two organizations signed mutual cooperation agreements. The agreement stipulates that in order to benefit the mutual interests of both parties, the two organizations should enhance understanding and long-term cooperation, maintain the relationship between manufacturers and members of the association, technically communicate with pump users, share pump statistics worldwide, and build the Atlantic Ocean. Cross-strait and cross-border business contacts.
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