There is vast potential for energy savings in vacuum systems, as many paper machines suffer from poor energy efficiency. Some machines would benefit from a complete system rebuild.
But in other cases, the required modifications can be relatively small compared to the savings gained. One often overlooked factor lowering efficiency can be the lack of maintenance.
The benefits of regular and correctly timed vacuum system maintenance are obvious. When properly maintained, the operational efficiency of the vacuum system is kept at an optimum level, and unexpected shutdowns are avoided. It is important to also service the auxiliary equipment.
In the papermaking process, providing vacuum is an essential requirement. Still, producing vacuum is always a complex and cost-intensive process. The cost of energy used by a vacuum system over its lifetime exceeds its purchase price many times over. This means that working at the optimum settings of a vacuum system is one of the most important economic factors in mill operation. If left untouched over long periods, the availability and efficiency of a system will decrease, and operating costs will inevitably increase.
By maintaining your vacuum system, you can keep efficiency at an optimal level and secure the stable operation of your papermaking line.
Extend service life and reach the highest performance of liquid ring pumps
To operate at an optimum level, a Nash vacuum pump needs to be well installed with a pre-separator. It also needs clean, cold operating water and no chemicals in the air being drawn in or in the water. In these conditions, the pump only needs some fresh grease for the bearings every 6 months. The service life of the pump bearings is around 100,000 hours, which is 10–12 years.
When the installation is good and the water is clean and cold, Nash pumps have a lifespan of thirty, forty or even more than fifty years. If the installation of the vacuum pump is not correct, the operation water is not of the specified quality or is too hot, then there will be problems with the vacuum pump sooner or later. The problems can vary in type, and maintenance is required.
Pump cleaning is an essential, and often overlooked, method of ensuring performance and efficiency. Over time, limescale deposits can develop within the pump, adversely affecting flow and performance.
Having the equipment checked regularly is crucial to maintaining perfect efficiency and optimizing energy consumption. We offer a complete range of inspections, maintenance and repair services that can be done either on site or at Nash state-of-the-art Service Centers. Our service team can perform a detailed pump inspection to gain an in-depth understanding of the problem and develop a tailored action plan to repair the pump and optimize it for the application.
Our Pump Exchange Program offers a way to exchange an existing pump with an overhauled pump from our pump pool. This allows the mill to keep the operation running.
Fiberscope inspections allow us to track the wear and condition of the pump internals without having to dismantle the unit. We recommend having the pumps checked at certain time intervals by a specialist. In this way, any damage can be detected at an early stage. This information helps you accurately plan maintenance and schedule and anticipate any repairs before any breakdown occurs, saving time and money by reducing the risk of unplanned downtime.
The standard Nash vacuum pump in the paper industry is made of gray cast iron. Due to certain circumstances, such as chemicals in the process or in the water, no pre-separator available and much more, the life of a normal gray cast pump is very short. In such cases, we have the option of coating the inside of the pump with a two-component ceramic or cladding them with stainless steel.
Secure maximum efficiency and stable turbo blower operation
RunEco EP Turbo Blowers are economical to own and operate. But as with any other equipment, to assure trouble-free operation and long life, regular turbo blower maintenance is recommended. The turbo blower impeller can become dirty and cause an imbalance. A dirty impeller also reduces turbo blower efficiency.
Basic maintenance requirements for EP Turbo Blowers consist of a bearing unit exchange and washing the impellers every 18 months. In addition, oil and oil filters should be changed every four months. Regular washing of the EcoDrop water separator lamellas and replacing the cooling air filter are recommended.
Runtech provides different service models, ranging from a basic bearing unit exchange to predictive maintenance, including measuring the bearing vibration spectra. An extended maintenance package contains all the key parts and checks needed to keep the RunEco EP Turbo Blowers in perfect operating condition.
The extended maintenance package also includes a new bearing unit. This redesigned hybrid spindle bearing tolerates abnormal running conditions better and minimizes premature bearing damages.
The extended maintenance can be conducted during a two-day shutdown. Runtech provides a complete report and spare part recommendations. After extended maintenance, we recommend standard maintenance at 18-month intervals and extended maintenance every 5 to 7 years.
We provide high-quality spare parts for your needs. Our original and inspected spare parts guarantee maximum performance. A fast and reliable spare part delivery is our priority.
Making life better with a service agreement
Regular, planned servicing not only provides peace of mind, it also helps you with cost management and improves the efficiency of your vacuum system. We offer tailored service agreements for both vacuum pumps and blowers that are designed to meet your specific needs. This additionally gives you access to our full range of services.
The typical length of the turbo blower service agreement is 5–10 years. The agreement allows for an extended warranty and ensures that used spare parts are of the latest model. In addition, individual maintenance does not need to be ordered separately.
End of life?
When the existing vacuum pump or blower reaches the end of life, there are several options for how to go forward. Units can be replaced with new ones or be upgraded to the latest or a different model, depending on the process requirements. In some cases, a complete rebuild is needed to gain better energy efficiency or cut down on water consumption.
With the experience of thousands of vacuum system audits and dewatering studies at paper mills, we are able to benchmark the effectiveness of existing vacuum systems, dewatering equipment, suction elements, fabrics and felts. All information comes together in an often step-by-step rebuild or upgrade plan that results in minimized operational expenses coupled with a production increase and/or runnability improvements.
We are the only company in the world that can supply both liquid ring pumps and dry vacuum systems, or a combination of them, for a so-called hybrid system. In addition, we offer doctors and save-alls, making our offering complete for paper machine dewatering. With this unique portfolio, we can always find a perfect fit for our customer’s demands, needs and budget.
Over 100 years of experience with vacuum systems
As the original innovators in liquid ring technology, Nash has over a century of experience in designing, manufacturing and working with vacuum pump and compressor systems. During this time, we have developed extensive knowledge of how our products work in a wide range of industries and applications – as well as an expert understanding of our customers’ plants, equipment and processes.
The Runtech Systems story started from a group of papermaking professionals, dating back to 1989, when the company began to offer paper machine optimization services. Today, more than 850 Turbo Blowers have been sold globally.
This experience and expertise allows us to work with our customers, help them get the most out of their vacuum pumps and blowers, compressors and systems – and ensure they achieve both their operational and process goals.
Source: Runtech Systems