Client: A manufacturing facility with a viscous product, changing in viscosity from winter to summer, making consistent flow difficult.
Industry: Manufacturing and industrial processing
Challenge: Recurring pump failures due to mechanical seal issues and viscosity fluctuations.
The client’s rotary lobe pump, while handling flow reasonably well, failed repeatedly due to mechanical seal breakdowns. Upon inspection, Thomson Process found that the pump wasn’t robust enough for the application, and maintenance issues were present. Even with proper maintenance, the pump’s performance didn’t meet the demanding requirements.
Solution: Thomson Process recommended replacing the pump with a Viking Pump Hygienic Revolution 1300X CPP pump, a more robust circumferential piston pump. Its smaller clearances provided better handling of viscosity changes, ensuring a more consistent flow. A new motor gearbox was matched, and the base plate was custom-designed for a drop-in replacement, aligning with the existing infrastructure.
However, despite the upgrade, seal failures continued due to crystallisation over the seal faces. A simple single mechanical seal was insufficient. To resolve this, Thomson Process installed a double mechanical seal system with a seal pot, preventing crystallisation and protecting the seals. This modification solved the problem and ensured smooth, reliable operation.
Outcome: The client’s pump system, initially failing every few months, now operates efficiently without further issues. Seal replacements are rare, and the client’s team is trained for occasional maintenance. What was once a costly problem has been transformed into a reliable, cost-effective solution.
Summary: Thomson Process stands by its customers to deliver lasting solutions. By addressing both the pump’s robustness and seal issues, the system now runs smoothly, demonstrating our commitment to quality engineering.
