10 Questions You Should to Know about Slurry Pump Wet Parts Factory

Tobee® What can you recommend to increase safe operation of my slurry pump?

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Apart from the usual guarding of rotating components, it is important to get advice from the manufacturer or their dealer. This is especially true if buying a Slurry Pump secondhand &#; just because the manual says it was designed to pump 2,000 gpm, it may not pump anywhere close to that if the duty isn&#;t the same as the original. Each duty is very specific. Let&#;s say you installed the Slurry Pump and had the wrong size pipe, you could have a critical issue with material settling out, which may even cause the Pump to explode.

This phenomenon has been reported by the Mine Safety and Health Administration ( bulletin) as a major concern. If a condition occurs that blocks the inlet pipe and outlet pipe of the Slurry Pump, it is estimated that 40% of the energy from the motor will go to heating the contents of the wet end of the Slurry Pump. The heat rise can be rapid and steam pressure will build, and an explosion can occur. Confirming the correct flow rate to keep materials in suspension and maintaining the design percent solids and particle size can reduce this risk. Installing power and pressure monitoring sensors that are interlocked and/or alarmed are also advised. Tobee&#;s recently developed thermocouple device is another safety feature when fitted and alarmed.

Good process design, proper mechanical design of sumps and piping, and use of safety related add-ons are factors determining the safe operation of a Slurry Pump. The manufacturer is always the best place to start.

When I reduced the length of pipe line, why did the slurry pump trip out on overload?

Because the Slurry Pump is running at fixed speed and hasn&#;t been told that you removed a section of pipe, it will keep spinning away but now finds it is easier to slurry pump. If you look at your slurry pump curve, you will see that if you lower the head (resistance) that the Slurry Pump is pumping against, the new duty point will move to the right and the speed curve and head will intersect at a higher flowrate. The higher flowrate means more work is being done and thus power demand is greater. It would be the same if you reduced the height you are pumping to. The opposite occurs if you increase the head by adding pipe or vertical height to the discharge point. The danger with increasing the head without changing the speed is the lower flowrate that results, which may be below the critical setting velocity. Contact the slurry pump manufacturer if you are contemplating changes to any part of your slurry pumping system.

Can I use oil in my slurry pump bearings?

Tobee&#;s slurry pump bearing assemblies are designed around the use of grease lubrication - this means that the seals being used are not suitable for oil. It is more complicated to design for oil and any leakage is far more troublesome for both lack of lubrication and the spillage. Grease lubrication simplifies maintenance and is appropriate for the rpms typically seen in this type of equipment

I have an old slurry pump sump that my grandfather used in our old plant, can I use that for my new plant?

Rather than just say no, which would be the first reaction from any Slurry Pump manufacturer, let&#;s examine why you probably don&#;t want to consider this. From our perspective, 90% of problems are on the suction side of a Slurry Pump. Of those problems, 90% of those are associated with poor sump design, such as wrong wall angles (buildup in valley angles and corners), too shallow (vortexing), too big (settling and sloughing), too small (air entrainment, vortexing) and incorrect suction line (entrainment and NPSH issues). The science of sump design doesn&#;t start or finish with a cube or an old truck-mounted water tank &#; a correctly designed sump can save you many thousands of dollars in maintenance on your Slurry Pump, or even save a life.

My slurry pump bearings are running hot, what should I do?

How hot are they? Tobee&#;s slurry pump bearings are designed to run at a relatively high temperature &#; we set a maximum of 120 &#; (248 &#;). Possible reasons for bearings running hot logically include slurry pump bearing failure; however, typically there will be other symptoms, such as unusual noise. Bearing failure can occur soon after gland failure if slurry has entered the seal at the wet end of the Slurry Pump.

It may simply be a faulty bearing. Were original equipment manufacturer bearings used during the last repair? It wouldn&#;t be the first time that price over value resulted in low-quality bearings being substituted.

Failure, or symptoms of failure, can also occur due to high belt tension (drive end) or air entrainment or cavitation (wet end), which will ultimately damage the bearings. Confirm the temperature rise (rises over time or almost immediate) and ultimate temperature. Look for other symptoms, such as noise. Ensuring personal safety, use a listening stick against the housing for signs that the bearings are not running smoothly. Consult the factory with the range of symptoms. 

Fortunately, Tobee&#;s slurry pump bearing assemblies are simple to repair &#; purchase a bearing repair kit and follow the instructions. Be prepared with an oven for heating, but the assembly requires no preload settings &#; just locate the bearings in place, lubricate and put the end caps on, finish lubrication and you are done. 

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Preventive maintenance is always cheaper than emergency repairs. The increased cost of urgent parts and process downtime hits an operation in the pocketbook.

Even though it is always good practice to open up a pump for inspection, there are usually external signs of wear and tear because of the harsh environment in which pumps operate. By looking for these signs, an operation can minimize surprise pump failures and treat the issue(s) with planned maintenance. Automation can be used to alert you to some of these warning signs, while visual inspection is required for other warning signs.

Different seals have different levels of leaking at the gland, but there is a normal amount of leaking and there is an excessive amount of leaking. An operator needs to become familiar with what the leakage is supposed to be in order to identify an issue.

A simple adjustment may get everything back in order, or maybe a small repair is needed. Left alone, however, it will become a costly repair that could have been avoided.

In the aggregate world, most slurry pumps have replaceable liners to protect the main body of the pump. Depending on how the liners are worn, the pump can have leakage at the liners. If ignored, the slurry will eventually attack the metal casing of the pump.

Product leakage is a clear sign that the liners may be worn or damaged. Excessive leakage should be addressed immediately with an inspection for damage. In the end, it is a lot cheaper and safer to replace the liners than it is to replace the casing and the liners. 

A lot of energy is put into a pump in order for it to move the slurry through a pipeline, and over time that adds up. When power consumption increases, it is an indication the pump is working harder to do the same job &#; or even worse, working harder and delivering less. The added energy cost does not help, but the loss in production can be extremely harmful to the bottom line. 

A sudden change in power consumption, whether it is an increase or a decrease, should always be a warning sign that something is wrong. Monitoring a pump&#;s power usage and setting warning parameters are an important part of keeping a pump in good working order. The best way is to have an automatic trending system, but even just manually recording a data point can improve the situation. A structured monitoring program will put eyes on the equipment and can give an early warning.

If a piece of equipment does not have vibration, it generally means it is not operating. Some equipment (such as screens) has a high level of vibration. With a pump, high levels of vibration can be a sign of inefficiency or worn elements. Worn bearings, turbulent flow and inadequate foundations are only a few sources of pump vibration.  

Pumps can be equipped with vibration monitors, which will track the progression of changes or spikes. Much like watching the power consumption, vibration levels will tell a story about the condition of the pump. Even without automated monitors, a good operator paying attention will know something is different.

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The bearing assembly is an important part of any rotating equipment. Worn or damaged bearings can scar the shaft, cause vibration, create high noise levels, generate heat and decrease pumping efficiency.

Because of the noise and vibration, a worn or damaged bearing should be easily spotted by an alert operator. In cases of extended times between visual inspections, a vibration monitor should be put in place. A thermocouple or heat gun can be used to monitor the temperature level to give an early warning.

As any corrosion will rapidly accelerate the rate of wear, it is important to ensure the bearings are always well lubricated and not exposed to moisture.

Listening to a pump can give you a number of early warnings. One of these warnings alerts you to a different type of wearing caused by cavitation. Cavitation is simply the formation of bubbles or cavities in liquid, developed in areas of relatively low pressure around an impeller. Shockwaves form when these bubbles implode or collapse inside the pump, causing significant damage to the impeller, lining and/or pump housing.

Listen at the suction and discharge end of the pump; cavitation generally sounds like marbles are going through the pump.

The loud, squealing noise of loose belts is annoying, but the real harm comes from the heat generated that eventually causes the belts to fail. The slippage of a loose belt also causes a loss of energy transfer between the motor and the pump.

On the other hand, excessive tension or poor alignment will put a burden on the bearing assembly and the motor mount. Something is going to give, and it is usually the bearing assembly with increased wear.

Excessive tension can also decrease efficiency.

Certain parts are designed to wear out to act as sacrificial components to protect others. The slurry and operating points have a direct effect on the wear rate. As mentioned above, tracking energy consumption can indicate when the liners are wearing out, but nothing compares to physically examining them during downtimes.

When a process is stable, the liner wear rate should be predictable once a baseline is established. In this case, the passage of time can be a good sign of wear.

Liners will develop a pattern of wear under stable conditions. Unexpected wear points can direct you to signs of trouble, such as a highly turbulent flow passage, misapplication or sizing of equipment, incorrect operating points or unsuitable materials of construction.

Monitoring a pump&#;s flow rate has multiple advantages in relation to how well a process is performing, but it can also give insight into wear components within the pump. A number of issues can reduce the flow rate (such as obstructions), but consistent and long-term decreasing in the flow rate will generally be a reflection of worn liners and impellers.

Every pump has a Best Efficiency Point (BEP) on its operation curve. Knowing where your pump is operating on the curve in comparison to the BEP can give you a heads-up to potential problems. When a pump slips in its performance, as shown by the flow rate, it moves away from its BEP and increases wear and tear on the pump. 

Dependable flow meters can be a significant investment, but they can provide valuable insight for the process and pump&#;s condition. 

A pump will break down sooner or later, that is a given. When the same pump has repeated failures over a short period time, it is an indication something is substantially wrong. Whether it is the wrong pump for the duty, poor quality replacement parts or an improper repair procedure, it is a sign the overall pump installation needs to be reviewed.  

Tracking and documenting repairs can help pinpoint the issue and allow a long-term fix to follow. In many cases, a repurposed pump can be undersized or oversized for the application. Both of those situations can cause problems, as shown by the &#;Effects of operating a pump off its BEP&#; chart above.

It is a costly and frustrating lesson to learn, but when a pump fails multiple times in a short period of time, it is a good time to bring in the manufacturer for a review.

Without a flow meter, there is another method to monitor the flow rate indirectly. A constant flow rate in a constant pipeline volume will produce a constant line pressure. A change in line pressure may not tell you exactly what has changed, but it will tell you something has changed. When it comes to pumping slurry, unexpected changes are bad news.

Anyone who has been around pumps knows that air and centrifugal pumps are not friends. Air in the discharge may mean air went through the pump. Even if you do not hear it at the pump, cavitation may be occurring. 

Dramatic swings in sump level can indicate a number of issues with the pump itself, but it can also cause problems to the pump. Since a centrifugal pump requires a head to operate, changes in the head (as shown by the sump level) can point to future and current problems.

While a pump is only providing material handling, the downstream equipment usually requires that the slurry fall within specific parameters. In the case of a Hydrocyclone, changes in the flow rate will change the cutpoint of the cyclone. Air in the line will disrupt a Separator&#;s ability to form a syphon.

When downstream equipment is not functioning properly, the overall performance of the process can be severally harmed. A pump is an important part of any wet process system, and when the pump is not performing, the signs show up everywhere downstream.

The pump will tell you when it is in trouble. You can listen for the whisper and have plenty of time to address the issue, or hear it scream in the middle of the night. 

For more information, please visit Slurry Pump Wet Parts Factory.