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Pump System Flow Reliability — ABB Launches Pump System Management for the Chemical Industry

| Author / Editor: Christian M. Stich / Dr. Jörg Kempf

In addition to the traditional life-cycle service for providing support of ABB products and systems, the company has launched an industry-specific service initiative for the chemical industry. Different business units in ABB and external partner pump and seal companies bundle their dedicated domain expertise. A comprehensive service package for pump systems is bridging the gap between the electrical and the mechanical domain.

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Industry-specific knowledge from all areas of ABB is bundled to develop joint services. The goal is continuous improvement in the existing plants, specifically the pump systems and their individual components.
Industry-specific knowledge from all areas of ABB is bundled to develop joint services. The goal is continuous improvement in the existing plants, specifically the pump systems and their individual components.
(Picture: ABB)

Material transport is one of the core requirements in the chemical industry. Pumps are the critical elements to ensure the transport of liquid material in continuous as well as batch wise production mode. The proportion of the total lifecycle costs increases continuously. Most of the installed pumps are old, so they cause enormous costs in terms of energy consumption, maintenance and investment of new spare parts.

Pumps Designed Years Ago Might not Meet Today's Standards

The pumps are designed years ago and do not reflect current requirements of production. They are not used in the optimal way with respect to the different requirements such as driving performance, material properties, integration in the process, and availability. About 80 % of the existing pumps are unregulated and therefore have no potential to fulfil the requirements mentioned above, which hampers process optimisation right from the outset. Examining the actual performance demands and the dynamic requirements of the process alone makes it possible to calculate the optimised operating point and thus allows the pump system to be operated at the highest overall efficiency.

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Available Pump System Concepts — a Question of the ROI

The correct design of pump systems and the early detection of possible failures increase the availability and reduce the operating costs. The cost of monitoring must be in relation to the risk and the value of the unit and requires examination of the following aspects:

  • Which are the most critical pump systems?
  • Do pumps work at the operating point and are they designed correctly in terms of the medium and all other process parameters?
  • Have redundancy concepts, maintenance concepts and available spare components for the pump system been planned and implemented?
  • Are measures for the early detection of faults made?

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