Pumps are used in virtually every sector, from food and beverage to pharmaceuticals. They play a critical role in many industrial processes, which is why pump failure is such a high-stakes problem. Failed pumps can shut down entire operations, leading to expensive repairs and production delays.
But what is a pump, and how, exactly, does it support operations? In this article, we’ll discuss the most common industrial pumps and how to prevent unplanned downtime and pump failure with precise alignment tools.
What Is a Pump?
A pump is a mechanical device that moves fluids or gases from one place to another. Industrial pumps convert the mechanical energy generated by the motor into hydraulic energy to create the power needed to transfer liquid or gas.
In addition to transferring substances, pumps also circulate fluids in heating and cooling systems, mix liquids during the production of food and beverages, and purify contaminated liquids.
Types of Pumps in Industrial Manufacturing
Broadly, pumps fall into two categories: dynamic pumps and positive displacement pumps.
Centrifugal pumps are the most common type of dynamic pump thanks to their simplicity and efficiency. The pump’s impeller rotates, creating a centrifugal force with enough pressure to move fluid through a pipe or a processing unit.
Submersible pumps are another frequently used dynamic pump. Also known as septic or sewage pumps, they transfer groundwater, waste, or chemicals from one location to another while being completely submerged in liquid.
Diaphragm pumps are positive displacement pumps designed to handle a wide range of fluids, including those that are mixed with solids. These pumps are common in wastewater treatment and chemical processing plants, and in settings where hazardous materials are present in fluids.
Piston pumps are a type of positive displacement pump that moves precise quantities of fluid under high pressure. They are widely used in hydraulic systems and in oil and gas facilities.
Peristaltic pumps are often used to transfer delicate fluids in laboratory settings. These positive displacement pumps keep liquids contained within a tube, protecting them from contamination. Industries that require high levels of cleanliness, like food and beverage or biotechnology, often use peristaltic pumps.
How Does a Pump Work?
All pumps work by creating a vacuum that pulls fluid in and moves it to a high-pressure area. Pumps use various types of impellers to create low pressure, or suction, which is necessary to transfer fluids.
A dynamic pump creates suction by rotating fluids in a centrifuge. The process creates a vacuum in the center which then sucks fluids into a pipeline. Positive displacement pumps, on the other hand, use pistons or diaphragms to create a vacuum by displacing fluids from a cylinder.
Pump components, especially impellers, mechanical seals, and bearings, are subject to wear and tear. Over time, this can lead to pump failure and unplanned downtime. Alignment issues between the pump and the motor can worsen wear and tear, cause fuel leaks, and eventually lead to pump failure.
Top Causes of Pump Failure
Pumps can fail for many reasons. The most common causes of failure include:
- Damaged or leaking mechanical seals, often caused by insufficient lubrication or a failure to prime the pump
- Blockages caused by dirt and debris
- Excess wear and tear on parts, especially the impeller, seals, and bearings
- Electrical faults, like voltage surges or power outages
- Misalignment between the pump and motor shafts, which can lead to excess vibration and premature wear and tear on bearings and seals. Even minor misalignments can cause major issues.
Best Practices for Pump Maintenance and Reliability
A combination of preventive maintenance and condition monitoring can keep pumps performing at maximum efficiency with minimal downtime.
Condition monitoring strategies include using meters and connected sensors on the pump to track temperature and vibration patterns. Changes in a pump’s vibration can indicate premature wear and tear on seals or bearings or impeller faults. Maintenance crews can also use meters to monitor the pump flow rate, which is a good indicator of overall pump health.
Preventive maintenance practices like regular inspections, cleaning, and lubrication are also crucial to maintaining pumps. In particular, it’s important to routinely check pump alignment using laser alignment tools. Pumps and motors can gradually become misaligned over time and should be routinely adjusted since misalignment is one of the most common root causes of asset failure.
Pump Alignment Tools
Misaligned pumps can cause a range of issues, from high vibration levels that cause premature wear on parts to seal faults and excess fuel usage.
Checking pump alignment used to be a time-consuming and challenging task. Fortunately, modern laser alignment tools make the process faster and more reliable, even for inexperienced teams.
Single laser alignment tools get precise, repeatable measurements every time so that teams can be confident in their results. The tools require minimal setup and can automatically correct inaccurate measurements caused by backlash, excess vibration, or environmental factors. The best laser systems come with touchscreens that guide users through the alignment process. Even new employees can get accurate readings with minimal training.
Maintaining pumps in precise alignment is one of the best ways to prevent unplanned downtime, reduce costly leaks and waste, and increase productivity throughout the plant.
