Feature Boilers, pumps & valves No shortcuts in pump maintenance


Mark Sumnall of Busch (UK) takes an in-depth look at how to avoid the pitfalls of cutting corners with vacuum pump service and gives his advice on efficient and effective maintenance programmes


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nsuring the right balance with service and maintenance budgets is something that should never be underestimated in all manufac- turing and processing environments. Often waste from materials used in the process (process carry over) can easily ‘clog-up’ equipment and establishing a maintenance programme to quickly identify any potential problems goes a long way to preventing break downs and lost production time.


While scheduling fewer periods of maintenance and reducing service programmes may seem like a good way of making savings, this is not ideal and there are ways of controlling costs, but without compromising on the quality and integrity of process. A well main- tained vacuum pump will always work more effectively and efficiently and use less energy, thereby saving energy usage and keeping bills down. Choosing equipment that is easy to clean and service will help keep main-


Pumps that are properly maintained will always work more effectively and efficiently


Top right: Using OEM spare parts will allow your pumps to operate more efficiently according to Mark Sumnall of Busch UK


tenance time down. For example, vacuum pumps designed for continu- ous use with tried and tested rotary vane technology, such as the R5 0302/0305 and 0400, are used in many manufacturing applications – particu- larly in food and beverage processing. An important consideration with vacuum pumps is to use original equipment manufacturers’ (OEM) staff to carry out servicing. This is not only important with vacuum pumps but is something that can also be applied to other key items of equipment through- out a factory. Using the reliable, skilled workshop engineer to under- take this activity may initially seem like a good idea, but in today’s high tech environment it is a good idea to ensure any such work is executed by the OEM service team, who really know the equipment and the specific technical features that need particular attention to ensure trouble-free opera- tion and maximum efficiency. For example, in the food sector, many end customers such as high street super- markets are now insisting upon OEM servicing to ensure all procedures are properly completed and this as arisen from incorrect maintenance in the past causing poor performance. In addtion, increasingly commercial and indus- trial insurance providers are requiring proof of OEM servicing due to some extreme cases where factory fires have been caused by incorrect and inade- quate maintenance procedures. Another crucial aspect of mainte- nance and servicing is making sure the


Steam injection raises temperature to cut corrosion S


team Injection Systems from Valveforce are helping a UK boiler manufacturer eliminate corrosion by raising and maintaining the temperature of feed water in the hotwell to reduce oxygen. Steam that is transferred to the hotwell via Valveforce’s steam injection system also helps prolong the life of the boiler. In addition, an oil and turbidity meter from Valveforce has been utilised for an important Byworth Boilers’ chemical industry customer. The meter is now part of a large replacement hotwell (designed,


manufactured and installed by Byworth Boilers), where it ensures that condensate is returned in good condition. Byworth Boilers’ sales & marketing director, Tony Green, says: “We are committed to designing and engineering the most fuel-efficient boiler solutions. Valveforce’s steam injection and oil/turbidity systems have been very reliable and we’ve also benefitted from Valveforce’s technical expertise in steam applications”. Valveforce


T: 0121 711908 www.valveforce.co.uk Factory Equipment MAY 2013 Enter 317 19


right spares are used for any repairs. If a replacement part is needed, sourcing a cheaper version may seem to be a good way of making savings. At the outset they may appear to be the same but looks can be deceptive and non- OEM parts simply don’t offer good performance. For example, in vacuum packaging applications, production and packing speeds will fall due to reduced air flow through the pump, with poorer end pressure and interac- tion between the backing pump and booster arrangements that are so often used in such situations. Additionally, oil mist can make its way through non- OEM oil mist filters, which will cause contamination problems and could also result in potential health and safety issues.


Non-OEM products may not last as long as the correct component and may prove to be a false economy. Equipment failure is also more likely, leading to loss of valuable production time and in some extreme cases, this can potentially cause factory fires. This in turn can result in weeks or even months of downtime, something that no manufacturer wants in these challenging economic times. Engineering and production man- agers can draw upon the knowledge and expertise available to them from OEMs. When looking to establish a new processing line, or upgrading and improving an existing arrangement, involving OEMs in the system design at the outset as well as with mainte- nance and service planning will ensure a smooth operation, while at the same time keep costs to a minimum. Busch UK T: 01952 677432 www.busch.co.uk Enter 316


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