Strategies to optimize pump efficiency and life cycle performance

Process pumps are one of the largest energy consumption in the plant and increasing the efficiency of the pumping system is a new shortcut for reducing plant operating costs. The ever-changing business climate is prompting businesses to make many changes to their traditional operating practices. Market globalization, demand adjustments, and stakeholder interests all require factories to find new ways to further reduce their production costs. In recent years, although enterprises are increasingly using information technology (IT) to improve productivity, such as enterprise resource planning and supply chain management. But while the factory is equipping its business systems with the latest IT tools, they are still using outdated and inefficient motor-driven pumping systems to run the production process. Today, inefficient motor-driven pumping systems are a weak link in the production process management. More specifically, the efficiency of a motor-driven pump system can play an important role in optimizing the production process. Although it is often overlooked, using technologies that increase its efficiency can dramatically reduce energy consumption and reduce maintenance and raw material consumption. For example: Pumped liquids typically consume the largest portion of the energy consumed by industrial motors throughout the pulp and paper lines and in the process. Optimizing the efficiency of the pumping system increases the stability of the pump and process, while achieving 20% ​​to 50% improvement potential for energy savings and reduced maintenance costs. In addition to hindering the overall increase in production efficiency, inefficient pumping performance can result in reduced product quality, lost production time, indirect damage to equipment, and excessive maintenance costs. Larger is not always better The productivity of the entire plant is often influenced by the correct selection, installation and maintenance of the pump system. Standard industrial practices often increase the size of the pump to ensure that it meets the needs of the process peak. In the past, this practice was accepted when the paper mill had a continual order need for all its forestry-based products. But today, things are different. The globalization of the market has led directly to excessive pulp product reserves and excess capacity. This change in situation determines that oversized selection of pumps should be re-examined. In 1996, a Finnish Technical Research Center released a report titled "Performance Analysis of Centrifugal Pumps." According to the analysis of 1690 pumps in 20 plants, the average efficiency of the pumps was found to be less than 40%, with 10% of the pumps Operating efficiency is less than 10%. Pump oversizing and throttling control valves were identified as the two main causes of excessive energy consumption. Strategies to Boost Pumps The initial purchase price for a process pump is typically less than 15% of its life-cycle cost (LCC). A 50 horsepower pump has a life cycle cost of installation, operation, maintenance and system downtime that is several times the original purchase cost. In general, energy costs can account for about 30% of pump life cycle costs and up to 40% for maintenance costs. If used for more than 20 years, the cost of energy and maintenance will exceed 10 times the initial purchase cost, and this part of the cost can be significantly reduced by increasing efficiency. The performance of the pump system is influenced by the following factors: • The individual efficiencies of the pump and its system components • The design of the entire system • The effect of the pump control • The efficiency of the drive section • Proper maintenance intervals The plant's system assessment helps to determine and quantify The best solution to improve pumping system efficiency. The most potential system improvements to improve efficiency are as follows · Improve motor efficiency through replacement and product upgrades · Best match for component selection and load requirements · Reduce motor load by improving process and system design · Replace pump speed adjustment Throttling Control Valves or Reflow Devices Also, the following features indicate potential for system efficiency improvements when performing pump system evaluations: Throttle valves, normally open return lines, all pumps in a multi-pump parallel system are always running, Constant pump operation in the process, presence of cavitation noise. Table 1: Control Valve and Speed ​​Control Development and Application of Intelligent Flow Control Inverters (VFDs) at the Same Flow Conditions, Especially for Intelligent Control of Pumping Control Applications Using Control Valves as Flow Controllers Operational practices have undergone major changes. In the past, frequency converters (VFDs) were used to reduce energy consumption or conventional control is not good. In fact, the Intelligent Pumping System is an optimized solution for pumping systems with intelligent software integrated into the drive's microprocessor chip. Smart drives keep the pump running close to its best efficiency point (BEF) and protect the pump from mechanical damage when the pump runs off its best efficiency point. The latest research shows that pump operation near the best efficiency point Pump efficiency and operational reliability have been dramatically improved. Table 1 compares the control valve differential pressure, pump speed and efficiency fluctuations under different flow needs. The intelligent variable frequency drive allows the pump to run at the optimum impeller diameter and at lower speeds, which further increases the reliability of the pump and results in a considerable improvement in mean time between failure (MTBF). In new projects, the purchase and installation costs of control valves are saved, followed by savings in energy and maintenance costs, which can result in a significant reduction in the total life cycle cost of the pumping system. Once in use, the intelligent variable frequency drive technology offers the following changes • Automatic adaptation to process variations • Automatic adaptation to changes in the pumping system • Pump protection in the event of system failure • Real-time condition monitoring is provided Sensor and control software is already installed Intelligent Pumping System Yes Provide smooth driving and productivity changes, are more tightly controlled during ongoing production, and provide more rapid diagnosis of potential problems with the system when it has no negative impact on product quality or process operation. As shown in Figure 1. Figure 1: Schematic diagram of the pump system, comparing the difference between a traditional pumping system and an intelligent pumping system. Energy Savings As shown in Table 2, in the pulp and paper industry, pumps consume most of the motor energy. In fact, the concentrated energy consumption of process pumps makes them the main choice for saving energy and reducing consumption. Table 2: Pumping system is a source of concentrated energy. Different types of process pump mechanical design will consider efficient operation. In practice, the design is designed to determine the size of the pump to operate at the point of maximum efficiency under normal operating conditions. However, process requirements and throughput requirements often change significantly over time. As a result, finding a constant speed pump to run at the best efficiency point is like "shooting a moving target." Flow pumps in all of the plant's rotating equipment have the greatest potential for energy savings. By intelligently controlling the motor speed in real time, the intelligent pumping system adjusts energy usage as needed. Through the motor speed adjustment to meet the precise process requirements, and to avoid unnecessary energy consumption. Case studies show that up to 50% or more of the energy can be saved by optimizing pump performance. In addition, consuming too much energy on a normal speed pump is not used on the pumped liquid, but rather on the pump body and results in reduced pump system reliability. In addition to reduced energy consumption, the biggest advantage of an intelligent pumping system is the resolution and elimination of recurrent operational problems encountered by the plant's production, maintenance and engineering departments. Under normal circumstances, the highest failure rate of equipment in the centrifugal pump, the seal leak is one of the longest production downtime and maintenance costs of the highest failure. Pump system optimization helps to reduce unplanned parking and increase production. Pump system optimization helps to reduce unplanned parking and increase production. & n

Light Emitting Diode SMD

SMD LED means surface mount Light Emitting Diode, SMD chip helps to improve production efficiency, as well as application in different facilities. It is a solid-state semiconductor device that can directly convert electricity into light. Its voltage is 1.9-3.2V, the red light and yellow light voltage are the lowest. The heart of the LED is a semiconductor chip. Encapsulated with epoxy resin. The semiconductor wafer is composed of two parts, one part is a P-type semiconductor, in which holes dominate, and the other end is an N-type semiconductor, which is mainly electrons. But when these two semiconductors are connected, a P-N junction is formed between them. When the current acts on the chip through the wire, the electrons will be pushed to the P area, where the electrons and holes recombine, and then emit energy in the form of photons. This is the principle of LED light emission. The wavelength of light is also the color of light, which is determined by the material forming the P-N junction.

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