The Significance of Pumps
Pumps are used to control the flow of fluids from one source to another. They are commonly found in the chemical, marine, energy and aerospace industries. Their applications range from pumping oil, water, fuel and gas.
Pump failure can lead to unexpected downtimes, costly repairs and disrupted manufacturing processes. This can cause reduced efficiencies, profits and performance for all processes in which the pump is involved.
The industrial pump market size is estimated at a worth of $62 billion in 2019, growing at a rate of 5.9%. This growth is accounted for by the use of pumps in growing industries such as wastewater treatment. Increasingly innovative solutions to treat pumps, such as adhesives, sealants and lubricants, are propelling this industry forward, allowing more effective solutions for pump failure.
Pumps are used to control the flow of fluids from one source to another. They are commonly found in the chemical, marine, energy and aerospace industries. Their applications range from pumping oil, water, fuel and gas.
Main Types of Pumps
Pumps come in various different types, which can be split into two main categories:
Dynamic Pumps
Dynamic pumps are a category of pumps that work by increasing the flow velocity in the fluid through the addition of kinetic energy.
One of the most common dynamic pumps used worldwide is the centrifugal pump. Centrifugal pumps increase the fluid’s velocity and pressure through the use of motor-driven rotors called impellers. Centrifugal pumps are relatively simple and low cost solutions to most pumping applications involving low-viscosity fluids such as solvents, water, light oils and chemicals.
Positive Displacement Pumps
Positive displacement pumps are a category of pumps that work by repeatedly enclosing a certain, fixed volume of fluid through the pumping system using seals and valves. The pumping mechanism of positive displacement pumps takes place mechanically through the use of diaphragms, lobes, screws, pistons, vanes and gears.
Positive displacement pumps are preferable solutions for pumping applications involving high-viscosity fluids such as slurries, thick oils, emulsions and biological fluids, especially when precise doing is required at high pressures.
Common Causes of Pump Failure
Pump failure can take place due to various reasons. Here we explore some of the most common ones:
Corrosion
Many pipes get corroded gradually as a result of the chemical interactions between the fluid and the metal pipe walls. The most common cause for this is the choice of material for the pump. Common cast iron pumps can function well in everyday applications, but present risk of corrosion if exposed to low pH or aqueous environments.
The best way to avoid this is by choosing a pump made of high-grade stainless steel, which has natural anti-corrosive properties. Additionally, anti-corrosive solutions, which will be discussed further down in this article, can help prevent and slow down corrosion.
Cavitation
Another reason for pump failure is cavitation, which is where some of the liquid in a pump turns into a gas at low pressures, creating unnecessary stresses and shockwaves within the pump. Once occurred repeatedly, this can damage the pump walls, leading to reduced efficiencies due to increased flow resistance. This can lead to the lifespan of the pump being drastically reduced, and eventually leading to total pump failure.
The best way to avoid cavitation is by ensuring your chosen pump has a Net Positive Suction Head Required (NPSHr) that matches the fluids that it will be used for. This can be found in the technical data sheet of the pump.
Cavitation is one of the common reasons for the failure of centrifugal and positive displacement pumps.
Vibration
High vibrations around the pump can sometimes damage seals, bearings and other intricate internal components, leading to pump failure. Damaged bearings are one of the most common causes of pump failure. This can be avoided by using vibration-dampening lubricants in the bearings of the pump, improving resiliency and durability.
Wear and Tear
Wear and tear are natural deterioration processes that happen to any mechanical component. The rate of wear and tear, however, will be accelerated due to improper lubrication of bearings, pressure imbalances and excess particulates in fluids within the pump. This can lead to a reduced flow rate and pump efficiency, and in the worst case causing total pump failure. Excess wear and tear can be avoided by using high-quality lubricants and sealants within the pump.
Mechanical problems, including wear and tear, are one of the common reasons for the failure of centrifugal pumps.
Leakage
Pumps can often leak their fluids as a result of improper sealing. Leakage can lead to deposit buildup, waste of fluids, excess rust and corrosion and reduced pump efficiency. This can be avoided by using high-quality sealants throughout the pump, ensuring no leakage takes place.
Fouling
Fouling is the process of particulates in fluids getting stuck to the pump walls, causing a reduction in flow capacity and efficiency. At its extremes, fouling can lead to pump failure. This can be avoided by using pump cleaners or pumping fluids that don’t contain particulates.
Top Solutions for Pump Failure
High-performance adhesives, sealants and lubricants can be used to protect pumps and prevent them from getting damaged. Here we explore a few of these products:
Krytox VPF 1506
Krytox VPD 1506 is a performance lubricant that can be used to reduce the risk of fire in pumps. It is non-reactive, non-flammable, and can replace any PFPE fluids as well as any other type of vacuum fluid. It can be used in vacuum pump applications where conventional oils cause safety and maintenance issues.
Krytox 1514
Krytox 1514 is a performance vacuum pump oil ideal for use in low-temperature pumps. It provides excellent pressure and temperature resistance and can be used in applications where conventional vacuum pump oils cause issues with waste disposal and safety.
Krytox VPF 1525
Krytox VPD 1525 is another performance vacuum pump oil which can be used to reduce the need for relubrication and time-consuming maintenance processes. It is non-flammable, inert and recyclable.
DOWSIL 732
DOWSIL 732 is a silicone adhesive and sealant that can be used for sealing joints and connectors for waterproofing pumps. It offers great adhesion to many substrates, is easy to apply and is stable and flexible from -60ºC to 180ºC.