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Find Out Which Pump is Best Suited for Wastewater Sludge Transfer?

The Crucial Role of Waste Water Treatment Plants Today, several industries across verticals are committed to sustainable practices that don’t have a negative impact on the environment. Companies that produce or use fluids in their industrial processes are looking for innovative ways to dispose of the byproducts without damaging the environment and disturbing the ecological balance. For instance, food and beverage processors, textile industries, chemical manufacturers, metal finishers and more generate fluids that have to be treated in accordance with local government regulations, before it could be discharged into the sewers or drains. Today, everyone involved in the process – customers, shareholders, government bodies and manufacturers and industrialists are all concerned about adopting sustainable practices. There’s an increased awareness on minimizing resources and impacts on the environment. Also, with water scarcity on the rise, more and more industries are looking for ways to recycle and reuse water. This is where, waste water treatment plants come into the picture. And, industrial pumps are at the core of all wastewater treatment systems. Positive displacement pumps are used to transfer waste liquids (along with solid sludge) from one tank to another, throughout the process. You need high-quality industrial pumps that can handle a range of wide fluids along with submerged solid particles. The Role of Positive Displacement Pumps in Wastewater Treatment Processes:
  • To transfer fluids from the sump to the reactor
  • To draw slurry from the clarifier tank and feed it into the filter press
  • For dosing chemicals into neutralizer tanks and the reactor
Here’s a Quick Working of Wastewater Treatment Plants The process begins in the sump tank. Waste fluids (remnants of industrial processes) accumulate here. A positive displacement pump is then used to transfer the fluid to a second tank, where the water flow is equalized and then pushed into the reactor tank. In the reactor tank, concentrated chemicals are added to the fluid to neutralize the pH levels. Here, a diaphragm pump or a metering pump is used to monitor dosage of chemicals. Finally, the neutralized liquid then flows into the flocculator, where special chemicals are added to particulates to make them coagulate at the bottom of the clarifier tank. While choosing positive displacement pumps for wastewater treatment systems, you have to consider both the composition and the temperature of the fluid, which passes through the system. Generally, there are four major pump options that industries use for sludge displacement. Each type has its own benefits and disadvantages. Let’s take a closer look at each of these four major categories of positive displacement pumps, from the perspective of sludge transfer.
  1. Centrifugal Pumps
They are good choices for transferring sludges with low viscosity and very little immersed solids. Centrifugal pumps generate significantly lesser pulsation, compared to the other positive displacement pumps on this list. Unfortunately, centrifugal pumps come with a higher shear rate. As you would be aware, shear on sludge is hampers the treatment process. During sludge treatment, wastewater treatment plants aim for high sludge concentration. If shearing happens, more sludge surface area is generated, which in turn disperses the solid substances, making it difficult to dewater.
  1. AOD (Air-operated Diaphragm) Pumps
AOD pumps are one of the most popular options for transferring sludge. The reason for this is that the operation of AOD pumps is quite simple and straightforward. The AOD pump has a single diaphragm which is operated using compressed air. Controlling the pump’s speed is really simple, and the fluid displacement outcome is also easily predictable. It’s ideal for producing a uniform and consistent sludge blanket, which in turn, produces consistent solid sludge. However, just like centrifugal pumps, AOD pumps too have high pulsation rates. As mentioned above, it uses compressed air for operation. If you don’t have an existing air compressor at the wastewater treatment plant, then operating this pump could become expensive, as you have to invest in an air compressor. On the other hand, if you have access to compressed air, then using this pump is relatively easy and inexpensive.
  1. Progressive Cavity Pump
This type of pumps handles sludge efficiently. They generate low pulsation rates and create zero to minimal shear on the sludge. While progressive cavity pumps come with high efficiency, repair and maintenance become highly difficult. However, of late, many pump manufacturers including Sintech are coming up with new progressive cavity pump designs that are easy maintenance. However, progressive cavity pumps have a bigger operational footprint. If you’re replacing an existing pump with progressive cavity pumps, then you’ll have to retrofit existing pipes to suit the new pump.
  1. Rotary Lobe Pumps
These pumps can handle fluids of high viscosity with ease. Just like progressive cavity pumps, rotary lobe pumps also have low pulsation and low shear. They come with a tiny operational footprint and accessing the interior parts is easy, via the front cover plate. While rotary lobe pumps may feel expensive initially, they are worth it. This is because the amount you spend on maintenance, repair and replacement parts for rotary lobe pumps is far lesser compared to progressive cavity pumps. The Last Word by Sintech Pumps Indeed there are plenty of options available to you for pumping wastewater sludge. Ultimately, it depends on several factors like – the position of the sludge in the treatment process, the budget available, type of sludge, air availability at the wastewater treatment plant and more. If you need further help with selecting the best positive displacement pump for sludge treatment, don’t hesitate to ask us about it. Our pump experts, here at Sintech, India’s most reputed sludge pump manufacturers, will help you find the right solution that meets your specific requirements.
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Causes for Pump Coupling Failures and Ways to Avoid Them

Shaft couplings are one of the most inexpensive parts of your pump system. Yet, they are one of the most critical elements. Very often, pump owners and operators don’t pay much attention to coupling selection. The result – frequent coupling failures, which in turn reduce pump operation efficiency and increase downtime. Here, in this post, Sintech Pumps – best pump manufacturers provides the Causes of Coupling Failures and the Ways to Avoid Them. What is a Coupling? It’s a device that is used to connect two rotating shafts in your pump system. If you’re experiencing frequent coupling burns and breakages, then it means that there’s a bigger issue with your pump. Coupling failures impact the reliability of your pump dramatically. If you’re experiencing coupling failures and replace couplings often, then continue reading to identify the underlying causes. Symptoms of Coupling Failures A coupling failure presents you with a few warning signs. Being aware of these signs will help you identify and spot coupling failure as soon as it occurs. If your pump demonstrates these symptoms, then it could indicate coupling failure:
  • Excessive vibration and/or noise
  • Increased power consumption
  • Bearing failure
  • Premature failure of the mechanical seals
Causes of Coupling Failure and Ways to Avoid It Let’s take a look at the reasons for frequent coupling failures
  1. Misalignment
This is one of the most common causes of a coupling failure. Misaligned pump or motor shafts lead to damage or breakage of the couplings. In fact, several studies state that misalignment is the reason for nearly 70 – 80% of pumps failing. Generally, couplings are flexible and can handle minor misalignments with no issues. However, like all other mechanical parts, couplings too come with limitations. If the misalignment goes beyond a particular degree, even a flexible coupling will fail. Make sure to check whether the shaft alignments are within limits specified by the manufacturer. If the shaft alignment goes beyond the manufacturer recommended levels, then make sure to do a laser alignment, before installing a new coupling. Some of the common types of misalignment of pump motor shafts include:
  1. Axial misalignment
  2. Radial misalignment
  3. Angular misalignmentMisalignment Types
 
  1. Torque Capacity
Just like alignments, all couplings have a torque limit. Torque failures account for 10-15% of all coupling failures. By miscalculating torque, you not only burn through couplings but could also end up damaging your pump systems. Too much torque at low-speed damages couplings. Make sure to consider both the steady state torque and instantaneous torque, while selecting couplings.
  1. Incorrect coupling selection
Unfortunately, most pump operators fail to prioritize shaft coupling selection while assembling a pump. In fact, it’s one of the most underappreciated and overlooked features of a pump. Incorrect coupling happens when you choose the wrong type of couplings or choosing couplings late in the application design process. A simple way to overcome this issue is by integrating coupling selection during the early stages of the pump assembly. If done, this could help you choose the right type of coupling based on requirement as well as aspect. This way, you can choose the right coupling size that suits the specific application requirements. If in the case, the application changes in the future, you have to revise coupling specifications.
  1. Environmental Causes
This is a rare cause of coupling failure. Exposure to harmful chemicals, excessively cold or warm temperatures, thermal expansion may negatively affect the life of your coupling. While these cases aren’t common, there are chances of them occurring.
  1. Improper Lubrication
Couplings made out of plastic, flexible rubber or magnetic metals don’t require lubrication. On the other hand, other types of couplings like grid and gear require lubrication. The lubrication levels of couplings must be checked at least once or twice every year. Make sure to flush out any contaminants from the lubricants to avoid premature failure of couplings. Final Thoughts – Coupling Failures can Impact Safety Make sure that your couplings are in perfect condition to avoid safety issues. When it comes to pump systems, proactive maintenance is vital. Ensure that you monitor your couplings regularly. If it requires lubrication or flushing, make sure to do it according to the schedule. Also, ensure that you select the right couplings for your pumps. This not only helps to increase the efficiency of your pumps but also improves reliability and uptime. Want to increase the reliability of your pump systems? Check out our diverse range of industrial pumps to find the best one that suits your needs. Talk to our pump specialists here at Sintech, to help you choose the right pumps that suit your specific application. We are one of the leading manufacturers and suppliers of industrial pumps in India and overseas.
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Looking to Reduce the Life Cycle Cost of your Pump Systems – Don’t forget to Consider these Factors

What is the Life Cycle Cost of a Pump? Simply put, it’s the total cost of ownership of the pump. It involves all the expenditures, right from the initial investment costs to ongoing maintenance and repair costs. All industrial users must do a Life Cycle Cost Analysis before purchasing a pump for their factory or plant. With that said, sometimes industry owners make the mistake of choosing a pump that comes with the lowest acquisition price, forgetting to consider the total life cycle cost. This can be a pretty expensive mistake, as ongoing and periodic life cycle costs are a major component of the buying equation. And, ignoring these, is a fatal mistake. The Three Main Components of Pump Life Cycle Costs Pump life cycle costs can be divided into three components:
  • Acquisition (Initial Costs)
  • Annual Expenditures (Maintenance)
  • Periodic (Repair and Replacement)
All these three components play a major role in determining the overall pump life cycle cost. While the acquisition cost is straightforward, the other two are a bit complicated and takes time to determine. Nevertheless, while purchasing a pump, you have to factor in all these three elements. Here, in this week’s post, we give you the best ways to reduce the overall lifecycle costs of your pump systems. Cost Saving Strategies to cut Operational Costs There are several strategies that you can employ to reduce the operational costs of your centrifugal pumps and rotary pumps. Here are a few of the top methods:
  • Always choose the right pump manufacturer
This is crucial because the right pump manufacturers would be able to provide you with the right pumping sizes that suits your requirements over a long term. Also, with the right pumps manufacturers you can be assured of getting repair assistance throughout your pump’s life cycle, not having to worry about replacing it. While choosing a pump manufacturer make sure to consider all the following factors – ease of use, reliability, part availability and consistent pricing. Additionally, try getting reviews from previous customers as to the trustworthiness of the supplier. Other factors to consider include warranties, pump operator training, repairs and more.
  • Look for pumps that come with a VFD (Variable Frequency Drive)
This helps you to alter the speed output based on the load requirement, instead of using parts that wear out prematurely.
  • Look for Pump Designs with Money Saving Features
Features like cartridge seals with reusable holders, reversible wear plates, and adjustable housing segments help in reducing the overall costs of a pump. While choosing pumps, spend a few minutes understanding all the features so that you pick the right ones that aren’t just suitable for your application, but also come with other advanced features that cut down operational costs.
  • Provide the Right Training for Pump Operators
Another main reason why you spend a fortune on expensive pump repairs is that the pumps were operated under the wrong conditions. To avoid such situations, make sure to provide the right training to pump operators. They must be able to decide whether parts need changing and if yes, do it on their own, or call in the right personnel for the job. Also, pump operators must know how to change oil and respect operational tolerances.
  • Invest in a few Sensors
You can install sensors that let you know of abnormal pump operating conditions. If possible, try to reduce the number of pump models in your plant so that you can cut down on inventory costs. Final Thoughts While low acquisition costs may appear advantageous in the outset, if your pump is going to need frequent repairs, it isn’t worth it in the long run. So, make sure to consider the total cost of ownership (which includes acquisition, ongoing and periodic costs) rather than the initial price. If you need any further help on choosing the right pump for your application, don’t hesitate to get in touch with us, here at Sintech, India’s leading manufacturer and distributor of a wide range of industrial pumps.  
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Reconditioning to your Rescue – Improve your Pump Efficiency & Make it Last Long

Though industrial pumps don’t undergo immense wear and tear, their performance takes a dip after a few years of usage. Worry not, Sintech Pumps provides reconditioning solutions to your rescue. Why Reconditioning? It can help your pumps last longer than their average life cycle. Also, reconditioning is highly environmentally friendly, as you don’t replace pumps but instead give them a new lease of life. Furthermore, the costs of reconditioning are significantly lower than the cost of a new pump. With reconditioning, you can restore the reduced capacity of your pump to its original level. Here’s a Bullet-point List of the Benefits of Reconditioning:
  • Your pump is restored to its original efficiency and capacity
  • All types of pumps can be reconditioned
  • No further modifications required to the foundations and piping
  • Lower cost
  • Eco-friendly
Is it time for a Pump Recondition? Here are the factors you have to consider before you decide to recondition your pump.
  1. System Requirements
Has your pump’s performance deteriorated to the point that it no longer meets the head and flow requirements? If yes, then your pump must either be replaced or reconditioned.
  1. Pump Deterioration Levels
Once you have determined that the pump’s performance has deteriorated, the next step is to find out by how much? In order to find this, you have to conduct a detailed pump system analysis, to help you find out the true performance degradation.
  1. What causes the pump’s performance deterioration?
Is the pump deterioration caused by the following elements?
  • Wearing ring clearance
  • Roughening of the pump’s waterways
  • The speed of the pump’s operation. Higher the speed, the greater is the impact or friction caused. (with higher speed, the flow is increased, while the head is reduced)
  • The magnitude of the water passages. Larger pumps can allow greater amount of roughness, while smaller pumps see a reduction in efficiency, with higher roughness.
  • Or other reasons
Answering the big question, Should the Pump be Reconditioned? Once you have determined the levels of pump performance degradation, the energy saving potential, the impact of the losses incurred due to internal leakage and increased friction, the cost of reconditioning, and the payback as a result of reconditioning – have to be charted to decide whether you should go in for a recondition or replacement of the pump. What are the Common Methods Employed for Reconditioning Pumps:
  1. Waterways
There are several aftermarket ways to recondition pump casings, impellers, and internal passages. Some of the most common techniques used are sand/grit blasting, wire brushing and coating.
  1. Wear Ring Clearances
Another easy way to recondition pumps is to replace wearing rings. This helps to not only improve the head and efficiency of the pump, but also reduces NPSH, since the turbulence and flow through the eye of the impeller is reduced. The lower the pump’s speed, higher is the impact of the wearing ring clearance on the pump’s overall performance. Where to Recondition Existing Pumps? If your pump is in need of reconditioning, make sure to approach your pump’s manufacturer who can accurately determine whether your pump’s efficiency can be improved with reconditioning or whether you have to replace the entire unit to improve the efficiency of the system. For any further queries, get in touch with our pump care experts, here at Sintech, the top industrial pump manufacturer and supplier in India. We customize pumps of all capacities to suit your requirements specifically. Give us a ring at 0120 417 6000 or drop in a mail at sales4@sintechpumps.com to know more.
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A Look at the Various Factors that Influence the Life of your Pump

Very often, here at Sintech pumps, we are asked this question by our customers, “How long will my pump operate?” Our answer remains the same, “It depends.” The lifetime of a pump depends on several factors including maintenance, operating conditions and more. Generally, pumps can operate for 15 to 20 years without any troubles and in several cases, it can even last longer, even up to 25 years or more, if it’s operated and maintained at the best operating points. Coming to the challenging question, what are the factors that end users can control to extend a pump’s life? Here, we present you with the top notable factors that impact the life of your pump.
  1. Radial Force
According to pump experts, one of the biggest reasons why centrifugal pumps fail is the wear and tear of mechanical seals and bearings. Consider the seals and bearings of your pump as the “Canaries in the coal mine.” These components act as early indicators of a pump’s health and help you get an idea of what’s happening inside the system. As any pump operator will let you know, the best practice is to operate a pump as close as possible to the BEP (Best Efficiency Point). When you operate your pump at the BEP, it experiences the lowest radial force possible. When you operate your pump away from the BEP, the radial forces generated will try to bend and deflect the shaft, which in turn leads to reduced bearing life.
  1. Oil Contamination
More than 85% of all ball bearing failures are a result of oil contamination due to either dirt or other foreign substances or even water. Adding just 250 ppm (parts per million) of water it reduces bearing life by 4x times. One of the critical factors in pump operation is oil service life. You can consider operating a pump similar to that of the operation of a car. Just like you have to change the oil after clocking particular kilometers in your car, you have to replace the oil in your pump regularly.
  1. Suction Pressure
Other factors that play an integral role in determining bearing life are driver alignment, suction pressure and pipe strain. Let’s take the case of a single-stage overhung process pump. Here, the resultant axial force on the rotor is pulled towards the suction, which in turn generates a counteracting suction pressure that further reduces the axial force. This reduction in axial force decreases the thrust bearing loads, which extends the Pump life.
  1. Driver Alignment
If the pump and driver overloads are misaligned it causes an overload on the radial bearing. The radial bearing life increases exponentially when calculated with the driver misalignment. For instance, even with small misalignment of just 0.06 inches, the bearing or coupling issues reduce months of operation.
  1. Pipe Strain
This happens when the suction or discharge pipe and the pump flanges are misaligned. Even if the pump has a robust design, the pipe strain can quickly transmit the high forces to the bearings, thereby reducing the life of the pump. The strain caused by the pipe make the bearing to be out of or incongruent to the other bearings, thereby causing the centerlines to be positioned in different planes.
  1. Properties of the Pumped Fluid
The key properties of the pumped fluid like specific gravity, viscosity, and pH all play a role in determining the life of the pump. If the pumped fluid is caustic or acidic in nature, the parts of the pump that come in contact with the fluid like the impeller and casing are likely to be corroded soon. Similarly, the density of the fluid (the number of solids suspended in it), the size and shape of the dissolved solids and abrasive qualities all determine the life of the pump.
  1. Mode of Operation
The severity of the pump’s service is also another major factor that determines the Pump life. The question to be addressed here is, “how often the pump will be stopped and started during a particular time?” For instance, pumps that are stopped and started every few seconds are likely to be worn out faster than pumps that operate continuously. If your mode of operation is such that the pump is shut down and started in quick succession, then you need to consider an alternative design that suits this particular application. In such cases, submerged pumps work better than suction lift pumps, this is because the lift in the latter category requires more work.
  1. Net Positive Suction Head A/R Margin
The higher the margin of NPSHA (Net Positive Suction Head) over NPSHR, the lower are the chances for pump cavitation. Cavitation causes damage to the pump’s impeller, which in turn causes vibrations that affect the bearings and seals.
  1. Speed of the Pump
The speed of the pump’s operation is another vital factor in determining the life of the pump. For instance, a 750-rpm pump will wear out faster than a 350-rpm pump.
  1. Impeller Balance
When the impeller is unbalanced in a vertical or overhung pump it causes a condition called as Shaft whip. This deflects the shaft just like a radial force. Sometimes, both shaft whip and radial force shaft deflection can occur at the same time. For ideal operation, the impeller must be balanced according to the standards defined by the ISO (International Organization for Standardization). If the impeller gets trimmed for any reason, it must be rebalanced.
  1. Pipe Geometry
This denotes the mode of loading the fluid into the pump. For instance, using a vertical elbow in the pump’s suction side causes lower deleterious effects than a horizontal elbow. This is because the impeller is loaded evenly causing the bearings to be loaded evenly.
  1. Pump Operating Temperature
Whether you use a cryogenic or hot pump, the operating temperature, especially the rate at which the temperature changes have a large effect on the reliability and the life of the pump.
  1. Casing Penetrations
One of the reasons why casing penetrations are optional and not the standard recommended practice is because it influences pump life. Very often, customers have the casing drilled for vents, drains, instrumentation or gauge ports. Every time, you drill into the casing, it acts as a stress riser thereby opening the casing for stress cracks and corrosion. Final Thoughts – Pump Life depends on a whole lot of Variables While this list is in no way exhaustive, these are the top factors that influence the life of your pump. If you have any further queries on finding the optimal operating conditions for your pump, get in touch with our pump care experts, here at Sintech, India’s leading manufacturer and supplier of industrial and commercial pumps.
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IoT& Its Huge Impact on the Pump Industry – A Brief Look at what to Expect in the Next Few Years

IoT or the “Internet of Things” is the latest buzzword and is becoming a growing topic of conversation, not only in tech circles but even outside of it. Before we head into today’s article of how IoT impacts the Pump Industry, let’s start with understanding a few key aspects. What’s IoT? The broad idea of IoT is that a whole lot of traditional appliances are increasingly built with wireless internet connectivity. This means you can now monitor and control these devices over the internet with the help of a mobile app. Why is IoT popular all of a sudden? The reason for this depends on a lot of factors – increased broadband coverage, decreasing costs of building devices with Wi-Fi capability, Smartphone penetration and so on. Ok, what does it have to do with Pumps? As more and more devices are turning smart, from coffee makers to cars, the pump industry is no exception. Digital transformation and internet are changing the face of the pump industry completely. More and more manufacturers are experimenting with adding sensors and Wi-Fi devices to pumps. This helps in predictive analysis and equipment monitoring, thereby reducing high, unpredictable maintenance costs and expensive downtime. Let’s take a look at the factors that are driving the move towards IoT  enabled pumps.
  1. Convergence of Industries
Long gone are the days when industries were considered as stand-alone. In the era of globalization and rapid digitization, the lines between industries are blurring. The proliferation of smart devices and emergence of new business models are disrupting traditional industrial practices. Additionally, with increased access to the cloud and reduced prices of sensors, more and more pump manufacturers are looking to implement these new technologies in their products. 2. Emergence of Digital Technology Three trends play a crucial role in the increasing move to IIoT (Industrial Internet of Things):
  • Aging workforce coupled with aging systems. There is a severe shortage of skilled labour all over the world.
  • Global volatility and increasing competition mean that manufacturers have to adopt new technologies to stand apart from competitors.
  • Exponential dependence on data. More and more organizations are looking to collate data and use it to enhance operations further.
3. Increase in the number of connected devices From Smartphones to smart cars, all the devices that we use and interact with, are increasingly becoming smart. These technologies are no longer the domain of Hollywood science fiction. They are a reality and are frequently used by us. From lights that you can switch off/on even when you aren’t at home to fridges that alert you to purchase milk on your way home, more and more devices are becoming smart. All thanks to the rapidly decreasing costs of IC chips and sensors. Additionally, with the rapid proliferation of wireless technology, companies can now quickly transform conventional devices into smart ones by utilizing the power of the Cloud. Consumers are expecting more from their devices. They don’t want an appliance that performs just the primary function, but they are looking for extra features. This means, more and more pump manufacturers are looking to provide smart solutions to enhance the overall experience of the end-users. 4. Evolution of Service Models Traditionally, most businesses followed a preventive maintenance service model. However, one major drawback of this model is OPEX (unnecessary Operational Expense). This has forced more organizations to move to a proactive maintenance model. When combined with the lack of a skilled workforce and the efficiency of predictive analytical solutions using data points means that more and more pump manufacturers are looking to adopt these new technologies to offer enhanced solutions to their users. So, how will a Smart Pump of the Future look like? Here, we give you an example of what pumps will do shortly. Your system pump will be outfitted with several sensors that measure everything from flow rate, pressure, vibration, temperature, current and voltage. All the data from these sensors will be passed to an IIoT gateway. There can be several such gateways depending on the complexity of your application. The gateway (or gateways) then aggregates the data from the sensors and decides whether to trigger any pre-set event alarms. When you move from a manual maintenance routine to an online monitoring system, like the one illustrated above, you get plenty of benefits.
  1. Your workforce need not spend their working time, moving around, checking existing systems and measuring data. Instead, they can use the accumulated data managing and diagnosing assets.
  2. Real-time data analysis is possible. This means you get the chance to spot any malfunctioning as and when it occurs, instead of further damaging the system.
  3. Additionally, sensors send data to the cloud only when something is out of the normal range. This means you don’t require a huge bandwidth to operate your pumps. After all, there’s no point streaming terabytes of data from a healthy pump all the way to the official cloud.
You can increase pump uptime and reduce overall operating cost with the help of these self-diagnosing sensors. Simply put, the sensors continuously monitor both, “What’s going to break?” and “When it’s going to break?” This is highly helpful to maintenance engineers in a power plant, water treatment plant or any other industry. They get a clear idea of what’s wrong and how long it will take for them to fix it. Additionally, the pumps of the future will be able to tell you explicitly what’s wrong with them, so you can fix them quickly and get the system up and running in no time. Are you ready for the pumps of the future? Get in touch with Sintech, the leading industrial pumps manufacturer, and distributor in India, for customized solutions across industries. Ring us at +91-120-4176000 or drop in a line at sales4@sintechpumps.com for more info.
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A Step-by-Step Guide to the Proper Boiler Feed Pump Selection for your System

What are Boiler Feed Pumps? As the name implies, Boiler feed pumps (also known as feed pumps) supply a boiler, a nuclear reactor or any other steam generator with feed water that is proportionate to the amount of steam generated. Majority of the boiler feed pumps in use today are centrifugal pumps. Earlier, they were made of unalloyed steels, but today boiler feed pumps are made with steel that has a chrome content of 13-14%. Today, boiler feed pumps have a rotational speed  even more than 6000 rpm, thanks to erosion and corrosion resistant materials like chrome steels that have anti-seizure properties and the advance in the technology of all pump components (including shaft seal, bearings and pump hydraulic system). Why the Boiler Feed Pump matters in an Industrial Steam Boiler? An industrial steam boiler is a highly pressurised tank. To avoid catastrophic failures, it’s essential that it always has the right amount of water. To ensure the correct water levels, the feed water pump must have a flow that is always higher than what’s required by the boiler for regular error-free operation. Additionally, other factors like the vented-receiver, temperature all have an impact on the mechanical design & seal of the boiler feed pumps. Steam boilers are used in various industries. They are available in a broad range of sizes, horsepower (100 to 1200) and design pressure (150 to 500 psig). ? Additionally, it’s common practice to use more than one boiler parallel to one another in several industries. Two Common Types of Feed-water pumping system designs are:
  • Direct Feed – This is the most commonly used system. It’s easy to maintain, and you can switch out a pump without impacting the rest of the system.
  • Booster Sets – In this type of system, there are no individual feed pumps. The boilers aren’t directly connected to supply Instead, there’s a booster set that provides water to a standard storage system. The water then moves from the common manifold to individual boilers with the help of a modulating feed water valve.
The Steps to determine the right boiler feed water pump for your System:
  1. Determine the control method. Check the specification of the system.
  2. Determine the base flow rate.
The formula to calculate base flow rate is: The maximum horsepower of the boiler * 0.069 * C You can find out the maximum horsepower of the boiler in the manufacturers manual. The value “C” depends on the mode of operation. C is 1.50 when the pump operates in an intermittent mode (on and off cycle), and C is 1.15 when the pump runs in continuous feed mode.
  1. Factor in the continuous boiler blow-down flow
This step is optional. It’s usually 10% of the pump’s best-efficiency flow rate; however, it can vary depending on the water treatment procedures. The continuous blow-down flow removes all the dissolved solids( silica content) from the water.
  1. Add bypass flow, if needed
Some systems use a feed valve and flow bypass recirculation line. The bypass flow ensures that the minimum amount of water passes through the pump at all times, thereby avoiding operation near to the shutoff head. This amount varies from one application to another but is generally 20 – 30% of the pump’s average flow rate.
  1. Determine the total flow rate
This is the sum of the base flow, continuous blow-down flow, and bypass flow.
  1. Calculate the base head for the feed pump
For the total dynamic head, make sure that you consider all the factors on both the suction side and discharge side. The formula is: Basehead in feet = 2.31 * 1.03 * maximum operating pressure of the boiler/liquid specific gravity
  1. Add all the suction-piping and discharge piping head components
Make sure you factor in all friction losses on both sides of the pump.
  1. Determine the total pumping head
This is the sum of the base head with the safety factor, discharge-side piping system head, and suction-side piping head.
  1. Calculate head at the boiler-safety-valve setting
Apart from reaching the correct head at the required flow rate, the pump must be able to achieve a shut-off head at the required flow rate.
  1. Find out the water temperature of the boiler’s feed-tank
  2. Calculate the net positive suction head
The formula for this is: Absolute pressure in the feed-water tank ± elevation of the minimum water level in the reservoir that lies above the feed pump – vapour pressure of the water – friction loss at the suction line
  1. Shortlist a few pumps
Make sure that all the pumps you choose meet the conditions listed above
  1. Check if the shutoff head is 3% or more than the safety-valve-setting
  2. Check if the net positive suction head is reached
  3. Ensure if the material of the pump is compatible
Check for both temperature and pressure compatibility. Once you have followed these fifteen steps, you can find the right boiler feed pump for your application. Not sure how to make the right choice? Worry not, just get in touch with our Pump Experts at Sintech to find the right boiler feed pumps that fit your system perfectly. Sintech Pumps are one of the leading industrial water pump manufacturers, and we supply pumps to several countries all over the globe. Get in touch with us by ringing us at +91-120-4176000 or drop in a line at info@sintechpumps.com.
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Why should you Learn to Read a Pump Curve & How to Do It?

If you’re new to pump terminology, then reading a pump curve may seem like a daunting task. What with all the lines and numbers, how do you make sense of them? Put your fears to rest! Here, at Sintech Pumps, we often get plenty of questions regarding pump curves and how to interpret them, both from beginners as well as experienced mechanics. This is why we decided to make this post a “How-To” on reading pump curves. By the time, you finish reading this, you’ll no longer be intimidated by Pump curve diagrams. Let’s get started! What is a Pump Curve? It’s one of the first things that you usually look at before your purchase the right pump for your project. Additionally, the pump curve is also a handy tool that guides you in the usage of the pump. To phrase it a nutshell, “the pump curve is a graphical representation of the pump’s performance. It’s what is to be expected from the pump, based on the testing conditions of the manufacturer.” Every pump has its own performance curve, and this curve varies significantly from one pump to another. Even the same type of pump will have different curves based on the manufacturer. The performance of a pump is dependent on the following three major factors:
  • Horsepower
  • Impeller size
  • Shape of the Impeller
Why use a Pump Curve? When you’re able to read and interpret a pump curve, you can quickly select the right pump for a specific application. Finding the right pump is essential if you want to extend the life of your pump by operating it at maximum efficiency. Additionally, reading a pump curve will also help you identify the limitations of the pump. Operating a pump beyond its given range not only damages the pump, but also leads to unnecessary downtime, which becomes expensive in the long run. Now, we come to the big question, How to Make Sense of a Pump Curve Aka How to Read It? Pump curves are nothing but graphical data that denotes a pump’s ability to produce flow against a specific head. Generally, the flow rate is on the X-axis (top and bottom), while the height required to push is on the Y-axis (sides). If you want to achieve a particular flow rate for your application, locate the required numbers on the chart. Then draw a line from top to bottom, that passes through your desired flow rate. Now, select your desired height by drawing a line to the right. You must now choose a pump, whose performance curve lies just above the intersecting point. Yes, it’s as simple as that. To help you understand better, here are a few terminologies used by Pump Curves:
  • Flow
This is the rate at which the liquid moves through your system. It’s measured in litre per minute or metre per hour in SI Units. In the US system, it’s estimated in gallon per minute. Different liquids have varying viscosities, which impacts the flow. Too much flow leads to noise and mechanical damage, while too little causes insufficient output. So, the key here is to find the right flow amount. Flow is denoted on the horizontal axis (X-Axis).
  • Head
It’s the total mechanical energy of the fluid at any given point in the piping system. The pressure in the system is measured as a pound per square inch. However, the hydronic pressure is measured as the head-loss. For your pump to displace the liquid through the system, it must produce a sufficient pressure differential, to avoid head loss. Head-loss is created due to friction between the valves and other fittings in the system. In SI Units, the head is measured in metres. In the US system, it’s measured in feet.
  • Performance Curves
A multistage centrifugal pump uses several impellers to create high pressures over several flows. The g curve on the chart represent the capacity & head developed by one single Impeller. To achieve the desired head, one has to divide the head required by the head developed by lone impeller. In multi stage pumps with say 5m stages the CAPACITY REMAINS SAME & ONLTY THE HEAD INCREASES.
  • Horsepower
Once you have identified the correct performance point, you can determine the right amount of horsepower that the system requires. On the left side of the curve, you can find the HP/Stage. This is a measure of how much horsepower the system needs at every stage.
  • Net Positive Suction Head (NPSHR)
This is a vital factor that plays a crucial role in proper pump operation. This is the minimum amount of pressure that you must input on the suction side to meet the positive pressure/head required by a particular type of impeller. This is called the NET POSITIVE HEAD REQUIRED(NPSHR). If the NPSH AVAILABLE isn’t adequate, you run the risks of cavitation’s, which affect the pump’s life and performance.
  • Efficiency
Efficiency plays a significant role in the selection of the best pump that is suited for a particular application. This indicates the percentage of the motor energy that is being expended for useful work. Low efficiency means that the energy is lost from the system as heat. There are several reasons for this loss like cavitation, friction, and recirculation.
  • Minimum Flow
All multistage and centrifugal pumps require a minimum amount of flow to dissipate the heat generated in the system. When you operate your pump, below this value, it causes severe damage to your pump components. Now, how do you find the Best Efficiency Point of a Pump? The general rule of thumb is the BEP (Best Efficiency Point) is 80% of the shutoff head. Ideally, you should aim to operate your point to as close to the BEP as possible. The BEP is mentioned in the pump curve. If you can’t find it, you can contact your pump manufacturer to get the value. Conclusion Knowing how to read and interpret your pump curve is essential if you want your pump to operate at maximum efficiency. Running your pump higher or lower than the curve, not only damages the pump and its components but also leads to excessive energy consumption, causing deterioration in the performance of the overall system. Have further questions about your pump curve? Get in touch with our Pump experts by giving us a call @ +91-120-4176000 or dropping in a line @ info@sintechpumps.com. Sintech is India’s leading commercial and industrial pump supplier, and we can provide you with the best pumps that are perfectly suited for your requirements.