How To Increase Pump Capacity

Centrifugal pumps play a key role in several industrial applications, from food manufacturing to chemical processing and oil and gas exploration. However, pump system efficiency may diminish with prolonged use, leading to lower overall productivity. This article will highlight the main reasons for lowered pump efficiency and tips for avoiding it.

Reasons for Decreased Pump Flow Capacity

A reduced pump flow capacity can be attributed to various problems that can be fixed with appropriate maintenance checks. The main causes of diminished pump efficiency are outlined below.

Reversed Impeller Rotation

As simple as it seems, a centrifugal pump with a motor running in the wrong direction can cause significant damage and limit the functioning of the pump system.

Component Wear

Like all mechanical systems with dynamic parts, centrifugal pumps are prone to damage from wear. Over time, impellers, rings, plates, and other pump parts can become worn, reducing the pumping capacity.

Read about wear ring clearance in centrifugal pumps.

Impeller Debris

Particulate debris stuck in a pump impeller can hamper its ability to create and maintain the proper internal pressures needed for optimal functioning.

Suction Clogging

Blocked suction piping is another common reason for decreased flow capacity. Clogging within suction units will hamper smooth fluid transport and diminish overall efficiency.

Valve Orientation Errors

Another major cause of poor pump functioning are wrongly oriented valves. For example, leaving a bypass valve open can easily divert flow from where it is needed. Similarly, closing suction and discharge valves can also limit pump flow capacity.

Disproportionate Clearances

Another reason for decreased pump flow is a mismatch between the fluid pumped and the clearances. Wide clearances will lead to higher slip rates and a drop in pump output.

Benefits of Increasing Pump Performance

Optimizing pump performance is beneficial for several reasons. To begin with, an increased pump capacity will translate to higher productivity for any associated processes. Also, larger flow rates due to pump performance enhancements are beneficial in large-scale operations where an increased flow capacity is required. Further, a properly optimized pump system will benefit associated process equipment, protecting them from damage associated with poorly performing systems.

3 Ways to Increase Pump Capacity

Every process operator should seek to maximize the efficiency and productivity of their processes. Commercial and industrial operations with pumping systems can benefit from these three tips to increase capacity.

1. Minimize Friction Losses

Dynamic fluids, regardless of their nature, are prone to friction losses—and process liquids driven by a mechanical pump are no exception. The longer and narrower the transport channel a fluid is channeled through, the higher the friction it experiences. This diminished flow translated to lower pump capacity/suction head.

Friction losses can be reduced by utilizing pipes with a wider bore and the shortest lengths compatible with the required application. This will reduce the drag caused by prolonged interaction between the inner surface of the transport channel and the process fluid being conducted.

Selecting the appropriate material can also help to limit friction losses. For example, polyvinylchloride (PVC) pipes generate less friction than steel. Therefore, it will be prudent to consider PVC piping unless steel pipes are an absolute requirement for the given application.

2. Parallel Pump Operations

Running a single pump can only generate a limited amount of suction head. Therefore, another strategy for improving pump capacity is to utilize two pumps running simultaneously. This technique involves operating two pumps connected in parallel to double the flow rate. Parallel pumping is particularly useful in subsurface drip system operations.

3. Evaluate Job Site Conditions

It is good practice to properly evaluate the environmental conditions in which a pump is expected to operate and adjust for maximum efficiency. A key parameter to consider is the altitude at which pumping operations will be conducted. Atmospheric pressure is exerted on every fluid. As the altitude above sea level is increased, the atmospheric pressure is reduced, limiting the amount of suction head generated.

Also, engine performance drops by about 3.5% with every 1000 feet of elevation added. Pump engines can be refitted to overcome reduced efficiency from rising altitudes by altering the air/fuel mixture used to power them.

PumpWorks Understands How to Increase Pump Capacity

At PumpWorks, we offer the best pumping solutions for diverse commercial and industrial applications that require them. We’re a leading manufacturer of American-made API 610 and ANSI pumps. Our highly trained and experienced team is available to provide all the assistance you need to optimize your mechanical pumps for your unique processes.

To learn more about how to increase pump capacity, contact us online today!