FEATURE PUMPS, VALVES & ACTUATORS SEAL THE DEAL WITH PIPING PLANS
Tom Grove, of AESSEAL, explains how a seal energy audit can help companies meet sustainability targets, as well as improve pump reliability and reduce operational costs
C
ompanies are increasingly making a commitment to energy efficiency by
appointing energy management or sustainability personnel, often at senior board level. Yet these companies remain unaware that the potential for significant energy waste may be embedded in operational equipment and processes. For example, mechanical seal friction
accounts for a tiny percentage of the total power consumption used on any one pump, so it’s easy to see how this key component can be overlooked by managers seeking to target energy losses and improve efficiency. Yet the energy consumed indirectly
through mechanical seal support systems can be considerable. These support systems or ‘piping plans’ supply a clean flush liquid to provide lubrication, prevent overheating and maximise a seal’s reliability. With the exception of gas- injecting seals, most mechanical seals will come with a piping plan. These generally fall into two main groups: • Flush, where clean, cool liquid is
injected into the seal chamber to improve the operating environment. • Barrier or buffer, where a secondary
fluid is fed to the space between two co- axial mechanical seals to prevent atmospheric contact with the pumped fluid, improve seal cooling, or enhance safety. With hot processes, cool liquid from a
flush system is injected into the process stream, removing heat, which must in
turn be reheated to compensate. Some piping plan configurations remove part of the process fluid and cool it in a heat exchanger before reintroducing it to the process stream, which all requires reheating. Evaporation may also be required where cool liquid has been added to the process, again leading to increased energy usage. The smart selection of piping plans is
therefore of great relevance across all industries looking to optimise efficiency and reduce costs. The International Standards Organisation
recognises the importance of energy management in the ISO-50001 Standard for Energy Management Systems. Businesses proactively committing to this standard recognise the mechanical seal as the ‘canary in the coalmine’ when looking to identify and reverse unnecessary power consumption caused by inefficient seal support systems. A simple and low-cost way to identify
this potential energy waste is by carrying out a periodic seal energy audit. This involves inspecting each piece of equipment, recording seal arrangement, support system configuration, process data and seal system parameters such as water flow and temperature. Existing plant data is collected and heat flow calculations performed, making it possible to calculate the energy impact of each individual mechanical seal on the plant, identify where energy use is high and review options for reducing it.
Seal energy audits make it possible to calculate the energy impact of each individual mechanical seal on the plant
An audit report is then produced,
providing the company with potential opportunities for a more efficient piping plan configuration, the investment required to upgrade and the potential returns. This also provides a ‘quick-win’ overview, highlighting low hanging opportunities which can deliver significant reductions in energy use for minimal outlay, while also improving the efficiency of seal and support systems and, consequently, pump reliability. Where flush piping plans are in place,
Tom Grove says that with the reliability, cost and environmental benefits a seal energy audit can bring, they should be central to the maintenance plans of companies with a focus on minimising
operational costs and maintaining their reputation as a sustainability-focused organisation
PC PUMPS CERTIFIED UNDER NEW EHEDG TESTING
In response to food industry demands for equipment that adheres to strict safety and hygiene requirements without compromising product quality, SEEPEX has developed a new hygienic progressive cavity (PC) pump range. The BCFH range is the first to be certified by the European Hygienic Engineering and Design Group (EHEDG) under its new testing regime. As well as giving end-users peace of mind that their closed equipment is microbiologically clean,
equipment designed to this standard typically requires 76% less cleaning time, saving on water, detergent and energy. The test methods for EHEDG certification are extremely rigorous: in order to meet the required standard,
SEEPEX’s BCFH pumps were used to process food that had been inoculated with microbes. The pumps were then cleaned at a lower temperature than is normal for standard CIP, before being stripped down and tested, to ensure every microbial trace had been removed. SEEPEX is the first company to gain EHEDG certification for newly developed, hygienic, progressive
cavity pumps under the recently revised testing processes. The new testing procedures will now be a requirement for all EHEDG-certified companies by 2020, ensuring that certification continues to provide end-users with complete confidence and peace of mind that the closed equipment they are using meets the highest possible level of hygienic design. SEEPEX
energy conservation goes hand in hand with water conservation for those companies which elect to upgrade to the environmentally friendly ‘continuous loop’ seal support systems developed in recent years. These manage water sustainably by employing an integral vessel to store flushing water for continuous recycling. The barrier fluid is circulated to and from the mechanical seal by thermosiphon, a method of passive heat exchange which circulates the fluid, minimising wastage and providing more efficient cooling. Because closed loop systems are
connected directly to the plant water line, which becomes the system’s fluid and pressure source, they protect the seal faces from harmful products, making them, and the pump itself, more reliable. Their financial impact can be significant.
For industries such as pulp and paper - where a typical paper mill can pump 6 litres of water per minute into pumps and systems, investment in a continuous loop water management system can achieve savings of over £400,000 and a ROI of 3- 4 months. Seal energy audits can also provide an
important communications bridge between the plant maintenance reliability personnel and operational stakeholders responsible for energy consumption.
www.seepex.com
AESSEAL
www.aesseal.co.uk
18 FEBRUARY 2019 | PROCESS & CONTROL
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