Each year, billions of dollars are spent on pumps used to introduce raw materials into various production processes or transfer liquids for storage or shipment to end users. Most pumps in service today feature mechanical seals, which are widely regarded to be the weakest point in the pumping system. More than 85 percent of pump repairs typically start with seal or bearing failures. For more hazardous applications, double mechanical seals help to prevent leaks, but they are expensive to maintain and repair. They often require a support system that needs a pressurized buffer tank to maintain higher pressure on the barrier fluid between the seal and the pump's stuffing box, plus piping and control systems that increase the size of the skid and the number of parts that must be maintained. Although double mechanical-sealed pumps should perform reliably for long periods of time, they inevitably require maintenance and eventual replacement. Replacing seals can be inconvenient, and the total costs add up in a number of ways. When measuring the costs of a leak in a chemical processing application, a good starting place is the lost productivity associated with service and repairs. Although pumps are often installed in pairs, taking a pump out for maintenance poses risks to a continuous production process, especially if the spare pump develops similar problems while the first pump is being serviced. Perhaps more important is the impact that leaks can have on employee health or environmental safety and the penalties, liabilities and remediation costs that come with chemical cleanup efforts.
A tank farm, an airport and one of the region's largest oil and gas companies are using the technology for a variety of applications.
12/03/2015
Image 1. One device uses ultrasonic technology to monitor the process liquids that lubricate the bearings in the sealless magnetic drive pump.(Images courtesy of Sundyne)
For these reasons, a growing number of companies across the Middle East are taking a closer look at sealless magnetic drive pumps. Sealless magnetic drive pump technology has been around for more than nearly 70 years, but it is only now starting to see rapid growth. Companies are beginning to recognize sealless magnetic drive pump advantages in terms of safety, reliability, simplified maintenance and lower overall costs. Many sealless pumps available today also comply fully to the commonly referred industry standards such as American Society of Mechanical Engineers (ASME) B73.3 and American Petroleum Institute (API) 685.
Image 2. A nonmetallic composite containment shell
The technology can also be retrofitted onto many existing sealless magnetic drive pumps, enabling the early detection of vapor, ensuring correct priming and venting, thus extending the longevity of the sealless magnetic drive pump.
This national oil and petrochemical company is currently using sealless magnetic drive pumps for a variety of applications, including caustic soda, sour water, aromatics and acids. Each of these applications pose challenges for sealed pumps, which are best overcome by adopting sealless magnetic drive pump technology.