Optimizing Pump Performance

Introduction

• Nick Daddabbo • Product Line Manager- Pumps• Its pronounced (Da Da Bo)…• 17+ years in Business Line/Product

Line Management• Xylem, Goulds Pumps, IDEX, SPX

• Over 12 years in Pump business line management

• Focused markets: Oil/Gas, Pharma, Chemical, Food and Beverage

World of Pumps Defined

Internal Gear$535

External Gear$858

Lobe/CP$324

Vane$459

Screw$1,028

PC$547

Piston/Plunger$1,337

Other$505

Peristaltic$452

Diaphragm (Dosing)$1,480

AODD$573

CAGR* 4.8%

64%21%

15%

Centrifu Positive

Oth

CAGR* 4.4%

World of Pumps

Positive Displacement Pumps-$8 BillionAll Pumps-$39 Billion

CAGR* 4.8%

CAGR* 3.9%

CAGR* 4.6%

CAGR* 4.8%

CAGR*4.8%

CAGR* 3.6%

CAGR* 4.3%

CAGR* 4.3%

CAGR* 4.3%

CAGR* 4.8%

Market growing in served technologies

CAGR* 4.75%

*Based on 4-year Industry Average CAGR, 2012-2016

CAGR* 4.5%

Future Isco

Source(s):McIlvaine,EIF, One Stone

Current Isco

The World of Pumps

• Pumps are used for a wide range of applications across many industries.

• An pump is usually used to move many different types of products, including water, chemicals, petroleum, wastewater, oil, sludge, slurry or food.

• The types of pumps typically used for industrial purposes includes centrifugal pumps and positive displacement pumps.

The World of Pumps

• Two major classifications of pump types:• Positive Displacement-physically draw fluid into the pump

at the inlet and force it out of the pump outlet.

• Rotodynamic (Centrifugal)-uses a rotating impeller to draw a vacuum at the inlet side of the pump and to send the fluid out at an increased pressure at the pump outlet

We will focus on the Positive Displacement type pumps in today’s discussion

Pump Considerations

Pump Installation Questions

• What type of process is the pump being installed into ?• Is it lab, scale/pilot or production?

• How much physical room do you have available where the pump will be installed?

• Do you have horizontal room? Dimensions?

• If it’s a hazardous area installation, what is the classification of the area? Adjoining area?

• Is there a long distance to cover from pump to controller?

Teledyne ISCO Pumps

Optimizing requires understanding of:• Physical/Mechanical effects on flow performance

o Leakage specifications/performanceo Mechanical variations – spring coefficientso Importance of displacement resolution

• Port/Tubing size effects on Refilling

Pump Installation Questions

• Fluid make up considerations:• Is the fluid being pumped considered aggressive or corrosive?• Does the fluid need to be heated, cooled or maintained at a

constant temperature?• Are there particulates in the material? (like biomass)• Does your fluid have particulates?• What’s the viscosity of the fluid?

Teledyne ISCO Pumps

Optimizing requires understanding of:• Fluid property effects on flow performance

o Pressure variations – compressibility – dampening effectso Temperature variations – expansion and contraction

• Effects on Refilling - viscosity fluids - cavitation

Pump Technology

Syringe Pump Technology

• Positive Displacement Piston Pumpo DC servo motor w/ Single speed gear setso Displacement resolutiono Mechanical errors effects less w/smaller

pistons

• Piston speed controlled separately for fluid delivery and refill

• Refill can be slowed down for viscous fluids

Syringe Pump Technology

Leak Sources• Cylinder cap seal - Static• Piston seal –Dynamic

o Circumference varies with pump model

• Cylinder – surface finish• Piston – surface finish

Port sizes• Tubing restriction

Fill Efficiency Definition

• Volume @ pressure/total volume

• Liquefied gases - 60 to 80% expected

• Liquids - >80%• Fill efficiency is most commonly

affected by high pump temperatures or empty supply tanks

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Syringe Pump Technology Overview

Model Max. Pressure

(psi)

Flow rate range (ml/min)

Flow rate accuracy

(set-point)

Maximum Leakage rate

(ul/min)

Displacement Resolution (nl/step)

1000D 2,000 0.001 to 408 0.5% 1.5 25.38

500D 3,750 0.001 to 204 0.5% 1.0 31.71

260D 7,500 0.001 to 107 0.5% 0.5 16.63

100DX 10,000 0.00001 to 50 0.3% 0.25 9.65

100DM 10,000 0.00001 to 25 0.3% 0.25 4.83

65DM 10,000 0.00001 to 30 0.3% 0.25 2.55

65D 20,000 0.00001 to 25 0.3% 0.25 2.55

30D 30,000 0.00001 to 22 0.5% 1.83

Special Considerations (ISCO Examples)

Note

The following special considerations are exemplified using Teledyne ISCO solutions

Continuous Flow

• Problem: Need continuously flowing material• Solution:

• Our current controller can manage up to four pumps at a time. (TB16)

• Many types of valve options.• Air vs. Electric

• Single Head vs. Dual Head pumps• ReaXus LS vs. LD

• Up to 100ml/min flow and 10,000 PSI• Similar performance and options

High Viscosity

• Problem: Material being pumped is viscous• Solution: If possible, heat fluid during pumping,

or use a larger port opening• HV pumps (TB18)

• Single or Dual versions available• Typically sold with air valves if in dual system• Capable from 300cps (motor oil) to 10000 cps

(molasses)• Standard larger ports…3/8 in.

• Heated jackets• ReaXus has options for heated jackets on the pumping

heads.

Corrosive Materials

• Problem: Pumping corrosive/aggressive materials

• Solution: Alternative pump construction• Available Material Types:

• Hastelloy-(Syringe Pumps/ReaXus)• Titanium • PEEK

• Also consider the material of the seal, valve, and all wetted parts

• Caution! Always check the corrosive chart for compatibility.

Fluid Structure.

• Problem: Keeping materials in suspension while pumping

• Solution: Install a mixer onto the pumping cylinder

• Mixer package• Consists of mixer, adaptor kit and cap• Designed to help keep fluids in suspension when

needed• Valid for 500D and 1000D• Currently only an air driven model is available• Impeller is designed specifically for ISCO• Application Note (AN25) addresses this topic

Sample Trouble Shooting/Solutions

Symptoms – Bubbles in Outlet

• Air not purged• Re-tighten all fittings• Ensure inlet line has fluid• Pressure leak check inlet line (high pressure tubing only)

• Inlet Line Leaks/Reservoir• Pump initial flow to waste• Pre-pressurize then flow to waste

• Cavitation/Low Vapor Pressure• Next slide

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Tips/Techniques – Cavitation/Vapor Pressure• Lowering viscosity

• Increase temperature (100C Standard – 200C option)

• Increase reservoir pressure• Pressure Pot• Pump• Gravity

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Symptoms – Flow variation

• Room temperature changes• Insulating cover – dampens temperature variation• Temperature Control Jacket - maintains constant temperature

• Pressure changes – Unstable back pressure• Plugging down stream – back flow – low temperature – in tube

reaction• Back pressure regulator – spring loaded

• Excessive time to reach steady state• Excessive time to reach steady state -Set pump to constant pressure then

switch to constant flow• Piston seal/cylinder leaks – Fluid loss

• Next Slide

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Tips/Techniques – Seal/cylinder Leaks• Leak check – 1 position -

Replace seal• Leak check – 3 positions

– replace cylinder• Leak check – after all is

considered

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Variety of Seals

Symptoms – Poor Refills

• Insufficient fluid • Larger reservoir• Poor fill alarm

• Low vapor pressure• Next slide

• High Viscosity• Next slide

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Tips/Techniques – Low Vapor Pressure/Viscous Fluids• Lower refill rate• Pressure pot• Larger Tubing/valves – ¼” – 3/8” – ½”

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Poor Fill Alarm

Pressing the soft key A to C turns feature on/off for pump. Numeric 1 to 3 change value in 10% increments from 10%-90%

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Application Notes/Technical Bulletins

• Metering Pumps – TB15• Field Verification – TB05• Temperature Control Jacket – TB07• Low Flow Operation – TB10• High Temperature/ High Accuracy – TB17• Diagnostics and Troubleshooting – TB22

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Questions?