Pump Industry Research Articles

A Major Disruptor in The Pump Industry

How additive manufacturing is disrupting the pump sector, offering increased efficiency, flexibility, and sustainability

Low-Voltage Water Pump System Based on Permanent Magnet Synchronous Motor

This paper designs a safe, low-cost, and efficient permanent magnet synchronous motor (PMSM) booster pump system. The aim is to enhance the pump’s safety and reduce the incidence of electric shock accidents, while also achieving cost reduction and efficiency improvement. The pump components are made of a plastic material, and a safe voltage of 36 V is used as the operating voltage. Additionally, the PMSM is chosen to replace the induction motor (IM) as the pump’s driving device, utilizing sensorless control and field-weakening control strategies. The study results show that when the flow rate is 1.51 m3/h, the efficiency of the PMSM low-voltage pump can reach up to 20.86%. At the same flow rate of 1 m3/h, compared to other pumps, the PMSM low-voltage pump exhibits higher head, energy savings, and efficiency. The proposed PMSM low-voltage pump offers advantages such as high efficiency, energy savings, safety, and low cost. This study provides a reference for the domestic PMSM pump industry.

Research on energy-saving and carbon-reducing technologies for water-ground source heat pump units

Abstract The heat pump industry’s energy consumption as a percentage of total energy consumption is constantly increasing. Research on energy-saving and carbon-reducing technologies, and manufacturing high-efficiency units of heat pump with water-ground source has become the main trend of the current heat pump industry. With proposal of the national “dual-carbon” strategy goal, enhancing the energy efficiency of units of heat pump with water-ground source has become a key way to transform and upgrade the refrigeration and air conditioning industry. The aim of this study is to combine current studies on energy-saving and carbon-reducing technologies for units of heat pump with water-ground source and applying these technologies. Through experimental tests, the energy efficiency of units of heat pump with water-ground source is more than 15% higher than that of ordinary units.

A ClearCareer Path

Ben Warren, a team leader on SPP Pumps’ Future Cell project and winner of the World Pumps-sponsored Rising Star Award at the 2024 Pump Industry Awards, tells us about his developing role and long-term goals

Flood Mitigation in Indonesia

A landmark project to provide flood mitigation for Jakarta receives the Environmental Contribution of the Year accolade at the 2024 Pump Industry Awards

A holistic methodology for mitigating awkward postural risks: Evidence from South Indian small-scale industries.

Small-scale industries (SSI) are the global economy's backbone since most industrial workers are connected. Most of these workers are contractual and temporary without appropriate training. Also, the SSI does not have a standard workplace with an appropriate layout and infrastructure, as they manage with minimum resources. Therefore, the work hazards, i.e., musculoskeletal disorders and fatigue, often go unnoticed as holistic postural risk methodology is still scarce for identifying the awkward postures in SSI. The present study proposes a novel holistic methodology to track and mitigate awkward postural risks in human-physical activities in SSI. To determine the effectiveness of the proposed methodology, a case study is presented in the South Indian Pump industry, wherein a critical workstation with a complex ergonomic work environment is employed. An ergonomic evaluation was conducted empirically and numerically in the workplaces using Digital Human Models. In numerical evaluation, three virtual workspaces have been created to redesign the identified crucial workstation, focusing on ergonomics and workflow. The results obtained from the case study are encouraging for to use of the novel methodology in SSI. The case study reports that the proposed design significantly reduced the REBA score and WISHA lifting index by 6 and 1.20, respectively, without significant investment. The proposed methodology could encourage research to identify awkward posture in SSI.

A Type-2 Fuzzy-Based Explainable AI System for Predictive Maintenance Within the Water Pumping Industry

Industrial maintenance has undergone a paradigm shift due to the emergence of artificial intelligence (AI), the Internet of Things (IoT), and cloud computing. Rather than accepting the drawbacks of reactive maintenance, leading firms worldwide are embracing "predict-and-prevent" maintenance. However, opaque box AI models are sophisticated and complex for the average user to comprehend and explain. This limits the AI employment in predictive maintenance, where it is vital to understand and evaluate the model before deployment. In addition, it's also important to comprehend the maintenance system's decisions. This paper presents a type-2 fuzzy-based Explainable AI (XAI) system for predictive maintenance within the water pumping industry. The proposed system is optimised via Big-Bang Big-Crunch (BB-BC), which maximises the model accuracy for predicting faults while maximising model interpretability. We evaluated the proposed system on water pumps using real-time data obtained by our hardware placed at real-world locations around the United Kingdom and compared our model with Type-1 Fuzzy Logic System (T1FLS), a Multi-Layer Perceptron (MLP) Neural Network, an effective deep learning method known as stacked autoencoders (SAEs) and an interpretable model like decision trees (DT). The proposed system predicted water pumping equipment failures with good accuracy (outperforming the T1FLS accuracy by 8.9% and DT by 529.2% while providing comparable results to SAEs and MLPs) and interpretability. The system predictions comprehend why a specific problem may occur, which leads to better and more informed customer visits to reduce equipment failure disturbances. It will be shown that 80.3% of water industry specialists strongly agree with the model's explanation, determining its acceptance.

Heat pump supply chain environmental impact reduction to improve the UK energy sustainability, resiliency and security

Various heat pump technologies are examined from an environmental perspective using a life cycle assessment approach. The investigated heat pump systems utilize air, ground, and water as their energy sources. Additionally, an innovative heat pump powered by green hydrogen is investigated in this study, to evaluate its environmental impacts and potential to commercialise on a large scale. A range of supply chain scenarios is explored, considering the main suppliers of the UK market. The reshoring heat pump industry and supply chain are evaluated to enhance energy resilience and security within the UK. The findings indicate that the hydrogen-based heat pump presents a promising option for the UK market, offering the advantages of reducing stress on the national grid network and minimizing the environmental impacts associated with the supply chain. Furthermore, a forecasting analysis is conducted based on the UK's net-zero emission plan to provide insight into future developments.

Design and Implementation of a Three-Dimensional CAD Graphics Support Platform for Pumps Based on Open CASCADE

In the pump industry, designers commonly utilize mainstream three-dimensional computer-aided design (CAD) software (Unigraphics NX 12.0 and SolidWorks 2023). However, these CAD packages are generic and not optimized for the specific requirements of the pump industry. This leads to a lack of flexibility and increased complexity in their usage, as well as higher computational demands, resulting in elevated learning and operational costs. Additionally, there are concerns about potential information leaks and software restrictions. In this paper, we studied the organization architecture of commercial three-dimensional CAD software, and compared and analyzed the geometric kernels and rendering engines of mainstream three-dimensional software. Using the Open CASCADE geometric kernel and OpenSceneGraph rendering engine, together with the Visual Studio 2021 development environment and Qt interface library, we developed an autonomous copyright three-dimensional CAD graphics support platform for pumps. Based on the three-dimensional platform, we tested the commonly used graphics elements and basic algorithms required for pump modeling, and successfully designed and modeled the impeller and volute casing of a centrifugal pump. Through computational simulations and experimental verifications, we demonstrated that the accuracy and precision of the pump model designed on this platform meets the design requirements, indicating that this platform has practical pump design and modeling capabilities. Compared to commercial three-dimensional CAD software, this platform exhibits superior flexibility and interactivity in three-dimensional modeling that is specifically tailored for pump products. Consequently, it fully satisfies the needs for three-dimensional parameterized modeling and visualization of pumps.

Was bietet die Pumpenindustrie der Welt nach Corona – Ein Rückblick auf die vergangene ACHEMA

AbstractAls erste Präsenz‐Messe nach der Covid‐Pandemie präsentierte sich die ACHEMA noch recht verhalten auf dem Messegelände in Frankfurt. Dadurch ergaben sich viele Gelegenheiten für den persönlichen Austausch mit den Kunden und Fachexperten. Eine Weiterentwicklung der Digitalisierung Pumpe 4.0 war weniger zu beobachten. Dennoch wurden viele neue Produkte präsentiert, von denen einige in diesem Artikel vorgestellt werden.

English

This research aims to investigate the process of gas tungsten arc welding commonly used in the submersible pump industry. The weld abandons is a noteworthy concern prompting revamp, greater expenses, and in this manner, influencing the conveyance plan of the activity. This research article succeeds in deploying the six sigma Define, Measure, Analyze, Improve, and Control (DMAIC) structure to improve the action features and assess and eradicate different sources in an operational system referred to in the industry. To implement the fundamental methods in various tasks, best usage instigation of availabilities, variabilities moderations, and maintaining the consistent output six sigma tool is adopted. The root cause analysis of Tungsten Inert Gas (TIG) welding defects and static tools to recognize the potential causes for controlling and supporting a few changes with proposals are specified. The current level of deformity was found to be 15% in stator rejections for the period of one month. After implementing the proposal, the overall defect was expected to reduce.

Meet the Association: Europump

Vanni Vignoli, president of Europump, discusses energy efficiency and contributing to a greener, more circular pump industry.

The study of the possibility of the pumping unit optimization for two operation modes, different from the optimal one

BACKGROUND: The study of factors affecting the vibroacoustic characteristics of pumps is one of the main areas of development in the current pump industry. Improvement of these characteristics allows to extend the service life of pumps by means of vibration levels reduction as well as to decrease the noise level.
 AIMS: In this study, the attempt to optimize the flow part of a multi-stage pump was made in order to obtain acceptable noise, vibration and harshness (NVH) characteristics in two operation modes that are different front the optimal one.
 METHODS: As the result of the study, it was found that changing these parameters in favour of NVH has a negative impact on the pump efficiency and vice versa. Thereby the optimal balance between these parameters should be found. The optimization was performed with the method of research of the parameter space with use of LP-tau sequences. The following elements were chosen as the optimization parameters: the area at the entrance to downstream, the angle of guide vanes at the entrance to the downstream, the width of rotor at the outlet, the angle of rotor vanes at the inlet and the outlet, the wrap angle of rotor vane. Decrease of the area of the graph of pressure pulsation spectrum was chosen as the optimization criteria. The mathematical model was verified with two designs of the flow part produced and tested earlier. The first sample has an overstated rate of the NVH spectrum in the area of high frequencies, the second sample has an overstated rate of the NVH spectrum in the area of low frequencies.
 RESULTS: The compiled mathematical model proved its good quality, showing the same results, which allows to speak about the admissibility of its use for optimization of the flow parts of pumps.
 CONCLUSIONS: This study will be useful for specialists in the field of vane hydraulic machines design.

An ergonomic evaluation of workers in the winding section of the pump manufacturing industry.

Work-related musculoskeletal disorders (WMSDs) are prevalent and have an impact across occupations. However, there are very few studies that document the prevalence of WMSDs in the pump industry. In manufacturing industries, the common issue for WMSDs and physiological stress among the workers is caused by poor working posture. To investigate the occupational risks at the winding station in the pump manufacturing industry. In addition, this study examined the influence of work-study on mitigating occupational risks. Workers who were involved in circular coil winding and insulation testing were considered for the study. Awkward postures adopted while performing these tasks cause fatigue, injuries and WMSDs. Tasks were evaluated as per the National Institute for Occupational Safety and Health (NIOSH) standards. A work-study was conducted to better understand the workflow. Virtual ergonomic postural evaluation (Rapid Upper Limb Assessment, RULA) was used to identify the occupational risks. Time taken for making circular windings and insulation testing (7.5 Hp submersible motor) was found to be 4.04 minutes and 0.95 minutes, respectively. A CAD model was used for ergonomic evaluation in the virtual environment. The RULA final score of 2 and 3 is attributed to coil winding and insulation testing. For further studies, the whole pump manufacturing process should be taken into account. The ergonomic tools used in this study will considerably reduce the occupation risks at the winding station in the pump manufacturing industry.

An insight into the problems, prospects and growth of pump industry in Coimbatore

Pump sets come under the essential commodities category, having huge market in India and across globe. The Pump industry is the oldest growing industry in the city of Coimbatore, which contributes substantially to Coimbatore’s GDP. Tamilnadu and Gujarat are the major pump manufacturing states in India. Coimbatore of Tamilnadu is called the ‘Pump City of India’ and it is home to all the leading pump brands like Aqua Pumps, Yathi Pumps, C R I Pumps, Texmo Pumps, KSB Pumps, Deccan Pumps and so on. Covid-19 has created significant impact on the industry; however, the pump industry is gradually regaining its demand. This study gives focus on the study of problems faced by the pump industry, the prospects and future of the industry.

Seasonal Efficiency of a Brine-to-Water Heat Pump with Different Control Options according to Ecodesign Standards

The seasonal performance of a heat pump indicates its average performance during the heating and/or cooling season, taking into account the different energy demands and their variability over time. Several European and international regulations and policies related with energy efficiency and the reduction of the carbon footprint of energy related products are affecting the heat pump industry. Among them, the ecodesign regulations impose minimum energy efficiency values for heat pumps, efficiencies that are based on the seasonal coefficient of performance. This work is focused on a domestic brine-to-water heat pump for low-temperature applications. The methodology to determine its seasonal coefficient of performance (SCOP) according to the European standard EN 14825 is explained and evaluated based on experimental results. The impact on the SCOP of using some technology options such as fixed or variable speed compressors, and fixed or variable outlet temperature operation is evaluated. Results show that between the lowest and highest efficient option, the SCOP can be improved by 26%.

The Amazon of Pumps?

World Pumps interviews Kai Stegemann, CEO of Star Pump Alliance (SPA) – a platform that helps users find the right application and technology for their individual needs – with plans to become the Amazon of the pump industry over the next 10 years!

Research and Test on Mathematical Model of Pressure in Pump Cavity and Balance Cavity of Centrifugal Pump

The pressure distribution law and calculation of impeller side cavity is one of the important topics in the pump industry, but there is no more accurate calculation method at present. On this basis, a mathematical model of pump cavity pressure distribution and balance cavity pressure under design conditions was derived in this paper. By changing the radial clearance of front and back sealing rings and the diameter of the balance hole on the same impeller, the pressure distribution of front and rear cavities and the balance cavity pressure of the pump were systematically tested by a specially designed device. In the test, the curve of pressure loss coefficient and relative radius of pump cavity under different sealing ring radial clearance was obtained, which could solve the calculation problem of the pressure distribution of front and rear pump cavities. The test curve of the relationship between flow coefficient ratio and specific surface area essentially reflected the coupling regulation effect of balance holes and the rear sealing ring on the balance cavity pressure, which could not only solve the calculation problem of the balance cavity pressure, but also provide the theoretical basis for controlling the pressure and cover force of balance cavity and select different combinations of the radial clearance of the rear sealing ring and the diameter of balance holes. The results showed that the theoretical prediction value was more consistent with the actual measured value, which proved that the proposed mathematical model has high accuracy and universality. This study provides a new way to more accurately calculate the pump cavity pressure distribution and balance cavity pressure and laid a theoretical basis for the study of impeller cover force with significant academic and application value.

Mergers & Acquisitions Review 2021

2021 was another strong year for M&A activity in the pump sector. This review lists the main pump-related M&A deals announced or completed between January and June 2021, from May River Capital's acquisition of Unibloc Pump to PSG buying Quantex Arc. The February 2022 issue of Pump Industry Analyst will cover the July–December 2021 period.

Pump Industry Award winners 2020/2021

Pump Industry Award winners 2020/2021