Whether pump can be used for Unloading and Loading ?

Site : Palm Oil Refinery
Unloading : From Truck Tanker to Storage Tanks
Loading Or Despatch Pump : from Storage Tanks to Truck Tanker

In a typical Palm Oil Refinery  in Malaysia . the pumps are usually located about 3 to 5 meter
away from Trucks , and the storage tanks are located about 200 Meter or more away from ths pumping station

For unloading , normally no problem

If the same pumps are to be used for pumping from stoarge tank to the truck tanker ,with a
suction line of 200 M or more , problem such as cavitation will arise due to NPSH avialable being too low
Possibly when  the tank level is high ,the pump may still work depending on the NPSH condition
When the level gets low ,serious cavitation occurs and this cause high reduction in flow ,pump noisy
and pump life gets shorten

Should there be intention for the pumps to be used both ways , the piping system must be designed to
suit the purpose ,that is taking into account the NPSH available for flow in both directions

STEP TOWADS INSTALLATION OF PUMPS

INSTALLATION &  FOUNDATION
1.1 Pumpsets must be propoerly installed,make sure the concrete is stable even and rigid
1.2 Pump Piping  should be properly supported  independantly and lined up accurately  with
the pump ports
Warning : never draw piping into place by force at the port connection of the pumps, severe
internal damages may result

1.3 Strainer of adquate size need to be selected and installed

1.4 Pump sets must be aligned

1,5 Instal flexible joints , vibration mounting pad etc

1,6 check rotation before starting the pump

NOISE LEVELS - ELECTRIC MOTOR

The Data in the table below represents average  test values .It is intended to serve as a guide in matters concerning noise and applies with a tolerance of +/- 3 dB(A)

Motor Frame
size                                         3000rpm         1450 rpm
rpm

63                                              53                     41
71                                              59                     45
80                                              60                     49

90                                              65                       54
100                                            69                       58
112                                            64                       58

132                                            69                       60
160                                            72                       62
180                                             73                      64

200                                            72                        63
225                                            74                         67
250                                            74                         67 

Sound Level under no load
Souce of  information : ABB Motor                                        

SOUND LEVEL - IMO SCREW PUMP (ACG 045 . 052, 060 .070 )

Typical Pump Sound levels referred to free field conditions at a distance of 1 meter from the pumps.
Noise of driver Excluded in the quoted figures . The sound levels are measured at a discharge level of
5 bar 2900 rpm ,Viscostiy 37mm2/s

Model         Connection                dB(A)
045            50 mm                         59
052            65mm                          63
060            80mm                          66
068            100mm                         68

Noise Level in Pumps

Various  contributing factors that will produce noises when the pumps are in operation, such as the following

Mechanical Failures
a)Misaligned Pumpsets such as
     - coupling misalignment
     - Pipework misalignment at suction / discharge
    - uneven concrete base

b )Bearing Problems
c) pump Problems, damaged by foreign material such as welding fluxes,bolts
    or metals entering the pump
d) Isolators or Vibration Mounting Pad Not installed
e) Flexible Bellows not installed


Hydraulic Failures

a) Caviatation , NPSH avialable lower than required by the pump
   
b) Insufficient flow reaching the pump , this is most common as most installer fail
   to determine the flow capacity of the pipe , ideal pipe diameter should be 80 mm
    for 450 Lpm or 27 m3/hr ( quick calculation , pipe velocity can be found in earlier posting)
A very recent case , customer upgraded pump capacity from  200 lpm  to 450 lpm
Previous suction line and tank outlet was 50 mm
However for this new installation, the tank outlet  and suction line remained  50mm
Discharge product goes close to the outlet of the tank , creating air pockets which get into
the pump causing Noises

Othe Factors
a) Pump & Driver Size
b) Operating Pressure
c) Pump operating speed

For Cavitation cases , the following could be done or rectified
a) Reduce flowrate by reducing speed of pump
b) enlarge suction line
c) increase product level in the tank
d) avoid air pockets going the tank bottom and into the suction line


Sound Level complying to manufacturer should be acceptable

Pumps for Deioned Water

Recently came across a Food Mfr with HACCP ,using pumps of Cast Iron Construction whereas piping system is in Stainless Steel
Is this right or engineer simply dont realise ?

If the pump is for pumping raw water to Deionised System , not too bad but still , we are giving unnecessary extra load to the filters in the system, with rust  ,extra

And if , the pump is for treated or Deionised Water ,then you are contaminating the water again

As the system builder has installed the cast iron pump , the user just follow the same replacment
without giving a thought

We do highlight , that  stainless steel pump should be used
What he said ? Expensive

And this happened despite Inspector from relevant food department audited the plant

HYDROSTATIC PUMP - MAX 60 BAR-MANUAL

HYDROSTATIC PUMP MANUAL OPERATION MAX 60 BAR

AMK OPEN IMPELLER PUMPS

AMK SERIES
OPEN IMPELLER
MATERIAL IS SS 304 OR SS316
PUMP SIZE , 3X 2 , 4 X 3 , 6 X 4
SOLID SIZE : MAX 30MM
SOLID CONTENT : MAX 30 %
SHAFT SIZE : 1 1 /2 '' FOR ALL PUMPS
SHAFT SEALING :MECHSEAL -SILICONE       CARBIDE
BEARINGS : DOUBLE BEARING FOR DRIVEN END
OIL BATH LUBRICATION
APPLICATION : CHEMICAL . EFFLEUNT .SLUDGE , WASTE TREATMENT

FOR HIGH CORROSIVE MEDIA , DRIP PAN BELOW STUFFING BOX  IS PROVIDED SO THAT THE CHEMICALS WILL LEAK ON THE CAST IRON BEARING BRACKET OF THE PUMP

EXTERNAL WATER FLUSH IS PROVIDED FOR THICK SLURRY APPLICATION

JACKETED (HOT WATER OR STEAM ) ARE AVIALABLE  FOR PRODUCTS THAT NEED HEATING UP , SUCH AS STEARIN . CPO ETC
STEAM TRACING IS NOT EFFICIENT AND SLOW TO HEAT UP

PALM OIL MILL - TREATED EFFLUENT LAND DISPOSAL OR COMPOSITE

Dear Zainuddin

As per your request , submersible pump is applicable for this job but take note as follow
a) pump impeller has to be non clog design, as the effluent will contain high solids and the solid content
depend very much on which  location of the pond you locate the pump

b) Submersible pumps are centirfugal pmps , and flow will dropped sharply if the discharge pressure
  increased , the Pipe is likely  to  be clogged due to scaling after sometime

c) if you are pumping about 1000kilometers away , need to work out the discharge pressure in the system carefully  or you may no discharge at the end

d) Two stage Progessive cavity pumps will be most suitable as it can handle higher solid content, positive displacement and max pressure of 12 bar

e) as this is not a production pumps , dont go for too big or oversize capacity as bigger pump means not only paying more for the pump but also higher maintenace spares . A capacity of 40 to 60 m3 hr should be  ideal

COOLANT PUMPS -CNC MACHINE

Recently came across a CNC machine running with small amount of coolant discharge from the pump
Checked and found
a) Pump is too small , only about the size of a coffee cup  and how much the flow we can expect ?
b) pump running on wrong rotation
c) although it may seem ro be alright , but lack of coolant accelerate the wear and damages of the tools
  and these tools can be expensive

The point here , is machine makers or users  failed to understand " quantity or flow in case " must be
right in any application

Suggestion : since there are few discharge nozzles around the millling tools and only one nozzle is discharging
                     coolant .the pump is definitely undersize .Determine the flow required from the manual or from
                     the pump at another machine which is big and performing . Replace the pump

Earlier Postings

FOR COMMENTS ON PUMP SELECTION  SIZING AND OTHER INFORMATIONS , PLEASE LOOK AT EARLIER POSTINGS

THANK YOU

USED FIREFIGHTING PUMP ( FOR SALE )

Dear All
One set of Firefighting Pump Model : EBSRAY 80-20 complete with 52 Hp Diesel

Engine in Tip Top Condition

UNLOADING HIGHLY VISCOUS -NON FLOWABLE MEDIA

VERTICALLY MOUNTED PC PUMP
FOR HIGH VISCOUS MEDIA
INK , GEL & PASTE

HYDRAULIC OIL FILTERING UNIT

SIMPLE PORTABLE HYDRAULIC OIL
FILTERING UNIT

NETZSCH PC PUMP FOR SKIMMER

FLOATING OIL SKIMMER IN PALM OIL MILL WITH NETZSCH PC PUMP

OUR SALES OFFICE

Recondition of Pumps - Coating

Pump sand blasted  Ready for coating and surface
preparation done according to
ISP 8501-01-ST3










Pump ready coated with Jotun coatings
Final Coat Alphatic Polyurethane
50 micron













Pump being undercoated before final coating
1st Coating with High Solid Epoxy 50 micron

Operating Cost of Pumps~ Energy

During the lifetime of a pump purchased , approximately 65 % of the cost goes to Energy , 5 % being the purchase cost of the pump and 35 % goes to maintenance & installation

Design the sytem head to optimum operating head, otherwise a bigger size pump and higher motor Kw is needed .
Result : higher maintenence and higher energy cost