Industrial Pumps

Selecting the right pumping equipment is essential for ensuring efficient, reliable, and cost-effective operations in water treatment plants, especially those processing waste and industrial water. This white paper outlines a 10-step approach for implementing pumping solutions in water treatment facilities that, once installed, require minimal intervention and provide seamless service over extended periods. Water treatment facilities encounter various challenges, including the handling of aggressive and corrosive chemicals and the need for continuous, reliable operation. A variety of pump technologies are available, each with unique designs suitable for different fluids, minimizing wear and tear and reducing maintenance needs. This document presents a strategic approach for integrating effective pumping solutions into water treatment operations to enhance benefits while reducing downtime and maintenance.

Step-by-Step implementation

01 Assessing needs and requirements

• Identify the specific needs: Seasoned design engineers fully understand the process requirements to deliver
  a reliable, accurate and low maintenance facility. Due to difficult accessible locations remote access,
  reliable equipment is mandatory, pumps are central to any water treatment facility with preference to
  remote pump performance data accessibility. These unmanned operations are becoming widespread
  adopted rapidly worldwide.

• Material compatibility: The pump material of construction and corrosive/abrasive compatibility, the hose/tube material, mechanical seals and exposure to the corrosive environmental factors all influence the selection of the suitable pump technology.

02 Selecting the right pump

• Pump Technology: Considering the difficulties with raw,waste- and industrial-water pose, it is vital to select the
  correct pump technology. Design engineers consider the chemicals used, the nature of the water source, the abrasiveness of the product /
  content, the solid content, the risk to clogging, gassing and crystallisation to name a few .

03 Design Integration

• System layout: The process map determines the correct location and duty for each pump technology used in a water treatment facility. Various pump technologies combine a fit for purpose installation and an overview of the pumps used in a water treatment that are the most popular choices include: 

1.  High volume transfer
   – A centrifugal pump
2. Chemical dosing
   – A peristaltic pump for corrosive compatibility
3. Chemical dosing pumps
   – Peristaltic pumps abrasive compatibility
4. Metering dosing pumps 
   – Peristaltic pumps for accuracy 
5. Chemical transfer
   – Air diaphragm pumps (subject to compressed air availability)

• Compatibility with existing systems: Due to variable water quality the rate of chemical application varies. Peristaltic pumps linear performance is most suitable whilst remaining almost perfectly volumetric efficient.

05 Use pumps that are application specific

• Off gassing liquids: Sodium Hypochlorite, Peracetic- (a disinfectant) and Fluorosilicic Acid (used for dental health) are known to form a gas. Peristaltic pumps can run dry, are self-priming and the ability to “pump” air presents the technology ideal to remain accurate in dosing these prone to gassing acids.

• Regular assessments: Peristaltic pumps eliminate the need for de-gassing valves or “switch to prime” function controls commonly seen in diaphragm and solenoid technologies.

• Abrasive chemicals: Lime or commonly known as milk of lime is synonymous with pH correction. Lime is by nature abrasive and detrimental to wear pump parts and mechanical seals. Characteristically, the internal section of the the rubber hose is the only part that makes contact with the liquid which protects the pump from abrasive or corrosive wear.

• Product shear: Flocculant manufacturers stress the importance to protect the polymer rheology, any breakage (shear) in the polymer strand affects the potential particle yield (ability to attract solids) the result will require a higher rate of flocculant dosing. Peristaltic pump low product shear is ideal for the dosing and transfer of flocculant and coagulant; the pump protects the polymer rheology to ensure maximum yield is achieved from the dosed chemical. The soft nature of carbon and some crystals benefit from the gentle pump action, the only product damage (as low as 1%) is derived from the shoe/hose compression point.

04 System Design

• Pumps: It is important to note, to correctly advise for optimum pump performance with the lowest maintenance cost the manufacturer require all static system details and not total dynamic head information.

• Pressure: Pulsation, the very nature of a peristaltic hose pump (less so in tube pumps) has various advantages and disadvantages. The calculation of system pressure must be derived from peristaltic pump principles and are technically unique from the pressure calculations in respect of traditional pump technologies.

• Information: It is highly recomended to engage with knowledgeable suppliers for expert advice and to share information in the correct mathematic selection of pumps..

06 Procurement

• Choose reputable suppliers: An original equipment manufacturer provides customers the best possible technical advice for the best suited pump technology and act as a consultant throughout the process.

• Spare parts and accessories: Using OEM replacement parts is highly recommended as the components are manufactured to original pump operational specifications using suitable materials to ensure OEM spare parts extend pump service intervals.

09 Future-proofed scalable performance

• Linear performance: Linear performance allow the designer to select a peristaltic pump with future duty requirements in mind. The combination of near perfect volumetric- and mechanical efficiency (as high as 85%) requires lower than average installed electrical power.

07 Professional Installation, Operational Testing and Staff Training

• Certified technicians: The simplicity of peristaltic technology must not be underestimated, considering the complexity of system design, the installation should always be in line with manufacturer guidelines for optimal pump performance.

• Installation and testing: It is beneficial to witness testing at a vendor facility followed by technical on-site pre, cold and hot commissioning assistance.

• Training: Operator and maintenance training complete the value proposition by extending on-site training or factory support training to ensure maximum pump performance.

10 Long-term Relationships

• Build a partnership, the transfer of pump ownership not solely a commercial benefit, but a partnership embedded by sharing ideas, continuous improvements (both in cost of ownership as well as environmental impact).

08 Monitoring and maintenance schedules

• Implement monitoring tools: Engineers increasingly seek the use of sensors and software to track pump performance, the integration of pump communication protocols into existing process control systems is essential.

• Alert mechanisms: An asset management software application can offer remote assistance (RA) with the development of internet of things (IoT) software. Pump conditions and duty parameters outline the foundation for the operator to remotely monitor and receive pump alerts.

• Maintenance simplicity: Easy hose and tube change guarantees hassle-free maintenance.

Conclusion

Selecting the appropriate pump technology is crucial for water treatment applications, balancing control, maintenance,
and dosing accuracy. Whilst peristaltic pumps may be suitable for specific needs, other technologies like diaphragm
pumps or centrifugal pumps may be more appropriate for others. The goal is to choose the most fit-for-purpose
solution that benefits all stakeholders.