Introducing a new pump to an existing industrial pump system is a delicate balancing act. There are several factors to consider, including the cost of the new pump, time for installation, and performance. Generally, industrial pumps are designed as "plug and pump" systems. This means they can be quickly introduced into an existing system without rewiring the original system from scratch.
As a result, installation experts and maintenance teams often falsely assume that introducing a new pump into an existing system has no impact. They assume that when the switch of the new pump is turned on, it will continue to pump perfectly, without affecting the rest of the system.
While pumps are designed to be "plug and play," there are several factors to consider while introducing them into a system. To ensure that you receive the full lifecycle benefit of the system, you need to get it right at the time of setup. The pump operators must understand the product thoroughly to make minor adjustments to ensure that the pump operates optimally with the rest of the system.
Taking time to understand the impact of the pump on the rest of the system delivers the following benefits:
It ensures greater system efficiency
Guarantees the longer lifecycle of the pump
Reduces operating costs
If the pump is not configured for the rest of the system, it can lead to several troubles down the line, shortening the lifecycle of the pump. This is why, at Sintech, we recommend that the person responsible for the long-term maintenance of the industrial system is present during pump installation. While the pump operator handles only the pump, the system maintenance engineer will have a clear picture of the overall system.
The system maintenance engineer needs to consider the following factors while a pump is introduced in the system:
Figure out the best way to introduce the pump in the system and bring it up to speed
Measure pump vibration and perform pump alignments wherever needed
Check if the pump is causing any visible stress on the system
Review the positioning and sequencing of various elements in the system to ensure that everything is working efficiently and properly
Top Pitfalls to Watch Out for, while Introducing a New Pump to the System
This is one of the biggest troubles while introducing a new pump to an existing system. Modern pumps with new-age technology are not likely to give alignment troubles. However, it still pays to be cautious.
Ensure that the pump is tested and adjusted for optimal operation. We highly recommend that you hire an installation expert recommended by the pump manufacturer. This way, the engineer knows the ins-and-outs of the pump and can resolve any minor alignment issues that crop up. It's a good practice to check for alignment to ensure the pump's optimal performance and improve its lifespan.
2. Grouting at the Base of the Pump
This is another common issue to watch out for. Pumps are designed to move liquids and fluids around. However, the pump must be securely attached to the base, and it shouldn't move around. The main objective of grouting a pump base is to reduce vibration and maintain structural integrity. Besides holding the pump in place, grouting also offers other benefits like:
Reducing wear and tear of the moving parts
Ensure that you follow the pump manufacturer's recommendations for grouting to secure the pump in place firmly.
3. Pump Speed
Introducing a new pump to the system puts stress on the rest of the system. So, you need to ensure that you introduce the pump slowly without overburdening the system. This is why pump manufacturers recommend using VFDs (Variable Frequency Drives). These drives gradually increase pump operation speed, thereby not affecting the rest of the system.
The golden rule to follow while introducing a pump into the system is:
"Close the discharge valve and ramp up the pump to the desired speed. Then, slowly open the discharge valve and ease the pump to the desired speed."
4. Force Installing Pieces Together
Force installing pieces to make them fit together places an unnecessary strain on the rest of the system. It can even lead to total breakdown and expensive repairs down the line. So, make sure that you do not force install a new pump to fit with the rest of the system.
5. Vibration Measurement
It’s a good practice to measure the baseline vibration of the pump at the time of installation. This helps to evaluate whether the vibration is within industry standards.
It's highly recommended that you use the services of a manufacturer recommended pump technician during installation. This will help you best understand how to initialize and install the pump to operate optimally with the rest of the system.
At Sintech, our job doesn’t end with selling the best-quality industrial pumps to our clients. We offer extensive and comprehensive after-sales support to each one of our clients. We walk you through the installation process and offer the best guidance to help you get the maximum out of your new pump systems. For further queries on installation or if you need help choosing the best pumps for your project, get in touch with our team at email@example.com.