Gene Vogel
Pump & Vibration Specialist
Electrical Apparatus Service Association, Inc.
St. Louis, MO
In his paper presented at the EASA Convention 2009, Gene Vogel emphasizes the importance of upgrading pumps rather than merely repairing them. He highlights the significant potential for improving pump efficiency, reducing maintenance costs, and extending the mean time between failures (MTBF). Vogel discusses various upgrade options that service centers can offer to enhance pump performance and reliability, ultimately benefiting both the service centers and their customers.
Vogel begins by discussing the concept of lifecycle cost (LCC), which includes acquisition, installation, operating, maintenance, repair, and downtime costs. He notes that while the purchase price of a pump is often the focus for end users, energy costs are the most significant component of LCC. By improving pump efficiency, substantial energy savings can be achieved, making pump upgrades a valuable investment.
Service centers can benefit from offering pump upgrades by generating additional revenue, achieving higher profit margins, and building customer loyalty. Upgrades that address efficiency and MTBF are less subject to competitive pressure and can provide better profit margins than standard repairs.
Vogel outlines several upgrade options, including surface coatings, shaft strength modifications, seal modifications, bearing isolators, and bearing housing breathers. Surface coatings can reduce friction, improve efficiency, and enhance resistance to abrasion and corrosion. Coatings for the inside of the pump volute and impeller can significantly improve pump performance. Additionally, coating the inside of the bearing housing can prevent contamination and extend bearing life.
Shaft strength modifications involve redesigning the pump shaft to reduce deflection and improve reliability. Shaft deflection can lead to seal leakage, accelerated bearing wear, and reduced efficiency. By increasing shaft diameter and using corrosion-resistant materials, shaft strength can be enhanced.
Seal modifications focus on selecting appropriate seal face materials and implementing effective flush and quench systems. Harder seal face materials, such as silicon carbide and tungsten carbide, are suitable for abrasive applications. Flush and quench systems, as outlined in API standards, provide cool, clean liquid to the seal chamber, reducing heat and contamination.
Bearing isolators and breathers are essential for preventing contamination and moisture ingress into the bearing housing. Bearing isolators introduce a labyrinth path for air entering the housing, while breathers with filters and desiccants capture moisture and contaminants.
Vogel concludes by emphasizing the importance of understanding the operating environment and customer needs when proposing pump upgrades. By offering upgrades that align with customer requirements, service centers can create high-profit revenue sources and strengthen customer relationships.
Key Points Covered:
- Lifecycle cost (LCC) and the significance of energy costs
- Benefits of pump upgrades for service centers and customers
- Upgrade options: surface coatings, shaft strength modifications, seal modifications, bearing isolators, and breathers
- Importance of understanding pump curves and customer applications
- Techniques for applying coatings and improving shaft strength
- API standards for seal flush and quench systems
- Preventing contamination with bearing isolators and breathers
Key Takeaways:
- Pump upgrades can significantly improve efficiency and reduce operating costs
- Service centers can benefit from additional revenue and higher profit margins
- Understanding customer needs and operating environments is crucial for successful upgrades
- Surface coatings, shaft modifications, and seal systems enhance pump performance and reliability
- Bearing isolators and breathers prevent contamination and extend bearing life
- Offering pump upgrades can build customer loyalty and create new marketing opportunities
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