Pump Maintenance in 7 Easy Steps

When things are running smoothly it’s easy to overlook common maintenance chores and rationalize that it’s not worth the time to regularly inspect and replace parts. But nothing could be farther from the truth. The reality is that most facilities have several pumps performing a variety of functions that are integral to the successful operationpump-image of the plant. If a pump malfunctions it can be the cause of an entire plant shut down.

Pumps are the cogs in the wheel that keep your facility functioning efficiently, whether they are used for manufacturing processes, HVAC, or water treatment. To keep pumps running properly, a regular maintenance schedule should be implemented and followed.

  1. DETERMINE MAINTENANCE FREQUENCY
    Consult the original manufacturer’s guidelines. Consider the timing to schedule your maintenance. Will lines or pumps have to be disabled? Select a time when the system is down and use common sense when deciding the time and frequency.
  2. OBSERVATION IS KEY
    Get to know your system and make a point to observe your pump while it is still running. Make note of leaks, unusual sounds or vibrations and unusual odors.
  3. SAFETY FIRST
    Make sure machines are properly shut-down before performing your maintenance and/or systems check. Proper isolation is important not only for electrical systems, but for hydraulic systems as well.
  4. MECHANICAL INSPECTION
    1. Check that mounting points are secure
    2. Inspect the mechanical seal and packing
    3. Inspect the pump flanges for leaks
    4. Inspect the couplings
    5. Inspect and clean filters
  5. LUBRICATION
    Lubricate the motor and pump bearing per manufacturer’s guidelines. Be sure not to over lubricate. More bearing damage occurs as a result of over greasing than under greasing. If the bearing has a vent cap, remove the cap and run the pump for 30 minutes before reinstalling cap. This will allow excess grease to work its way out of the bearing.
  6. ELECTRICAL/MOTOR INSPECTION
    1. Check that all terminations are tight
    2. Inspect motor vents and windings for dust/dirt build-up and clean according to manufacturer’s guidelines.
    3. Inspect starter/contractor for arcing, overheating, etc.
    4. Use a megohmmeter on the windings to check for insulation failure
  7. REPLACE DAMAGED SEALS AND HOSES
    If any hoses, seals, or O-rings show wear or damage, replace immediately. Using a temporary rubber assembly lubricant will ensure a tight fit and prevent leaks or slips.

International Products Corporation (IPC) offers a unique line of temporary rubber lubricants. Our P-80® lubricants are available in six water-based formulagroup-p-80s that offer superior lubrication and are compatible with a variety of surfaces. P-80 lubricants are environmentally friendly, most are biodegradable.
There are numerous lubricants out there, including good old soap and water, so why do you need specially formulated rubber lubricants?  The facts speak for themselves:

P-80 Lubricants

  • Reduces Friction by 70%
  • Provides superior temporary lubrication, is environmentally friendly, is safe for workers, and comes in many biodegradable formulas

Solvents

  • Reduces Friction by 30%
  • Provides poor lubrication, contains high VOCs, may be flammable, and poses possible health risks

Soaps and Detergents

  • Reduces Friction by 30%
  • Provides inconsistent, nominal lubrication and may reactivate when wet

Petroleum Distillates

  • Reduces Friction by 60%
  • Provides lubrication but is often incompatible with materials, leaves a heavy residue, and sustains lubrication

P-80 rubber lubricants are temporary, once dry the lubrication ceases and parts stay in place. Additionally, these lubricants will not reactivate in the presence of water and they will not dry out rubber parts.

Keep your facilities running smoothly. Try P-80 temporary rubber assembly lubricants for your pump maintenance needs. Visit http://www.ipcol.com to speak with a specialist and request a sample for testing. Download our free ePaper and case study discussing P-80 for pump seal maintenance.

All P-80 products are manufactured in the USA by International Products Corporation (IPC) and are readily available worldwide through a network of global distributors.
Contact IPC for a free P-80® sample kit by visiting www.ipcol.com or email parts@ipcol.com.  P-80 is available for purchase online at www.ipcol.com.

The Synergy of Membrane Cleaners

Water treatment facilities across a variety of industries are often challenged by membrane cleaning. As membranes become fouled from use they become less effective. Clean membranes allow for the proper flow of water. Keeping membranes clean is key to maintaining an optimal flux rate and helps to ensure that the treatment plant is operating effectively.

THE ECONOMICS OF MAINTENANCE
Treatment plant operators realize the importance of implementing a regular membrane cleaning regimen, but are often challenged to find the right cleaning products. Ideally they will want to find a cleaner that will restore membrane flux (which will in turn prolong the life of the membrane), reduce the cleaning frequency needed, be safe for both the membranes and the environment, and prove easy to use. Using the right membrane cleaner is a good economic decision as it minimizes downtime and prolongs membrane life. Since membranes are extremely expensive most facilities try their best to keep them operational for as long as possible.

Many membranes are sensitive to harsh chemicals and extreme pH levels. It is important for treatment plant operators to choose cleaners that will not be harmful to the membranes. Many specialty cleaners with mild pH ranges and safe ingredients are formulated to be effective, non-harmful cleaning agents for membranes.

THE RIGHT CHEMICAL IS KEY
Another consideration in choosing the proper membrane cleaner is the type of soil found in the water that is being treated. Alkaline cleaners dissolve oils and greases; some also contain chelants that can suspend metals and minerals. Citric acid cleaners are excellent at dissolving scale, like calcium carbonate or iron oxide. Hazardous acid cleaners, such as sulfuric, hydrochloric, and phosphoric, will serve the same purpose, but citric acid is much safer and has a broader range of filter compatibilities. A citric acid cleaner that also contains surfactants can go after many oils and greases that might be present in addition to the scale. In the food processing industry, soils can contain proteins and starches; in this case enzymatic cleaners might be needed. Most foulants are combinations of various soils; therefore choosing a formulated cleaning product with multifunctional ingredients is usually best.

AN UPSETTING PROBLEM
One U.S. wastewater treatment plant has an auxiliary effluent re-use facility constructed specifically to produce reverse osmosis quality water destined for ethanol production. The plant requires approximately 1,000,000 gallons (3.8 million liters) of reverse osmosis water per day above the wastewater treatment plant’s normal processing volumes. The wastewater control systems manager, manages the effluent re-use facility to ensure this additional volume is met on a daily basis. A key component of the effluent re-use facility is the ultra-filtration process, which uses 0.4μ polyvinylidene difluoride (PVDF) membranes with an upper pH limit of 10.0. These membranes are fouled primarily with petroleum sulfonates and bacterial secretions. Particularly in cold weather, the upstream BOD step has frequent “upsets,” where the bacteria die and secrete a water soluble foulant that adheres strongly to the PVDF polymer and significantly increases the trans-membrane pressure (TMP). These “upsets” must be resolved quickly to ensure a plentiful supply of pure water.

PASSING THE TEST
In order to determine the optimal cleaning regimen, the plant manager systematically evaluated the performance of twenty different cleaners and hundreds of differentmembrane_art_beaker combinations and concentrations, including commonly used commodities and many formulated membrane cleaners. The results found International Products Corporation’s Micro-90® was one of the top performing cleaners in the study. Micro-90® stood out because the product performed better than all of the commodities and other formulated membrane cleaners, particularly on the bacterial secretions. Micro-90® worked effectively without the use of phosphates, silicates, and strong alkalis, at a membrane-compatible pH of only 9.5, and at a 0.3 percent concentration.

THE SYNERGY OF MICRO-90®
Micro-90® is a mild, yet powerful, multipurpose, alkaline cleaning concentrate that has long been used in laboratories, industrial applications, and critical cleaning processes. Micro-90® is a unique chelating detergent that contains ionic and non-ionic ingredients, which combine to produce a variety of cleaning actions. Micro-90® lifts, disperses, emulsifies, sequesters, suspends, and decomposes soils, then rinses away leaving the surface absolutely clean.
Micro-90®’s target soils include oil, grease, wax, tar, flux, particulates, hard water stains, and biological debris. Micro-90® is highly effective at defouling filter membranes and can be validated in critical cleaning applications.

A MODEL FOR THE FUTURE
Micro-90® has been in use at the effluent re-use facility since October 2010. Some of the original PVDF membranes are still used and continue to smembrane_m90ee significant TMP drops after cleaning with Micro-90®. Although the bacterial upsets cannot be prevented, their fouling can be resolved in a predictable manner with the use of Micro-90®. Since the initial use of Micro-90®, the effluent re-use facility design engineers have recommended the cleaner to other similarly designed effluent re-use facilities nationwide because of the product’s effectiveness, safe profile, compatibility, and economical cost per use.

Because so many variables can exist in choosing the right cleaning product for each facility, it is important for treatment plant operators to work with cleaner manufacturers that can offer them technical guidance and a variety of products to best meet their needs. When selecting a membrane cleaner find a company that provides a range of proven products, referrals, free technical support, free product samples, and on-site assistance.

Micro-90® is manufactured in the USA by International Products Corporation (IPC) and is readily available worldwide through a network of global distributors. Contact IPC for a no-obligation evaluation and offer of free samples by visiting http://www.ipcol.com or email membrane@ipcol.com.  Micro-90® is available for purchase online at http://www.ipcol.com.

International Products Corporation appoints new CFO, William F. Herbert

International Products Corporation (IPC), a chemical manufacturer of specialty cleaners and temporary rubber assembly lubricants, is proud to announce and welcome William (Bill) F. Herbert as their new Chief Financial Officer, effective October 20, 2016.  bill-herbert-head-shot-hi-res

Bill brings over twenty years of work in Finance and Planning, most recently as CFO – Corporate Stores for Jackson Hewitt Tax Service in Jersey City, New Jersey where he was responsible for the financial performance of over 1,700 stores that generated over $95 million in revenue.  Prior to his tenure at Jackson Hewitt, Bill spent twelve years at Hess Corporation, Woodbridge, New Jersey, in the areas of Finance, Management and Planning.

Bill received an MBA from Vanderbilt University, Nashville, Tennessee and a B.S. in Engineering from Duke University, Durham, North Carolina. Bill has also served as a Lieutenant in the United States Navy.

Bill is “excited and honored to join the IPC team. I look forward to helping accelerate the company’s growth by building on IPC’s award-winning products and processes.” IPC President, Kathy Wyrofsky, believes “Bill’s experience brings to IPC the financial and operational skills necessary to assist in leading the company to substantial growth and success.”   

About International Products Corporation: International Products Corporation (IPC), founded in 1923, manufactures specialty cleaners and temporary assembly lubricants in Burlington, NJ. All of IPC’s products are free of hazardous chemicals and many of their products are biodegradable. They are equipped with state-of-the-art manufacturing, packaging, and warehousing equipment, and an on-site laboratory for quality, analytical work, and research and development. IPC is ISO:9001 certified and is dedicated to providing safe, high-quality cleaners and lubricants. All of IPC’s products are made in the USA and are readily available worldwide.

5 Reasons Why You Should Be Using Temporary Rubber Assembly Lubricants

How many times have you trepair-troublesried to push an O-ring into place only to have it pop right back out? Or tried to push a rubber hose into a pipe only to find it wouldn’t slide into place because the fit was just too tight? These tasks can be very frustrating and can often require considerable physical effort and time.

Rubber materials are inherently difficult to install, remove, or otherwise manipulate – even when wet. The slip resistant nature of rubber creates a challenge during the assembly and repair of rubber parts. Common assembly problems that may occur include ill-fitting, misaligned or damaged parts, rolling O-rings, uneven cuts, and worker injury. Using temporary rubber assembly lubricants can solve these problems.

Temporary rubber assembly lubricants can:

1. Reduce Installation Force:
A thin film of lubricant applied to a part fills in any gaps, holes, or spaces between two separate surfaces, allowing them to slide across each other. By reducing the surface tension between the two surfaces, rubber parts can slide into place easily, providing a tight fit.

2. Achieve Closer Fits:
Engineers can design lower tolerance parts. The force needed to install the parts when a lubricant is used is greatly reduced. Since the lubrication is only temporary, once dry, the parts stay in place resulting in a tight fit.

3. Improve Product Performance:
Improper part alignment can lead to part failure and safety issues. Using a rubber assembly lubricant, which enables the parts to slide easily into place, can solve these problems by reducing or eliminating damage to parts.

4. Increase Production Rates:
Applying an assembly lubricant to the rubber part makes the rubber slippery, so parts can easily slide into place. After the lubricant dries, the lubricity goes away and mated parts maintain a tight fit. The assembly process becomes more productive because it is easier and quicker.

5. Help to Avoid Worker Injuries:
Lubricants reduce the insertion force needed for rubber assembly. Workers can more easily push parts into place, reducing the amount of musculoskeletal, slippage, and repetitive stress related injuries that can be caused by using too much force to insert a rubber part.

The next time you’re having trouble replacing a pump seal, inserting a grommet, or pushing a hose into place, try using a temporary rubber assembly lubricant and see how much easier the job becomes. Temporary lubricants are ideal for rubber assembly because they reduce the friction needed to assemble parts.

Want more information about temporary rubber assembly lubricants, including how to use them and factors to consider when choosing a lubricant? Download IPC’s free P-80 webinar. Or contact our technical team at mkt@ipcol.com to help you find the best solution for your assembly needs.

CASE STUDY: P-80® Grip-it Quick-Drying Temporary Rubber Assembly Lubricant Allows Dishwashers to Pass Critical Drop Test

The following is a case study from a major appliance OEM. It shows how using the proper P-80® assembly lubricant assisted in reducing drop test failures. Assembled dishwashers routinely undergo post assembly drop testing. During testing, a number of failures occurred. P-80® Grip-it was trialed and selected because of its lubrication and adhesive qualities. Switching to P-80® Grip-it solved the problem by significantly reducing drop test failures.

CASE STUDY: P-80® Grip-it Quick-Drying Temporary Rubber Assembly Lubricant Allows Dishwashers to Pass Critical Drop Test

Test Results:

  1. P-80® Grip-it reduced failures allowing dishwashers to pass drop tests consistently.
  2. Easier assembly installation.
  3. Greater hose removal force.

Challenges: A dishwashing manufacturer was experiencing failures during their six inch drop test. Specifically, a connection of a return hose to the sump was susceptible to excessive tangential stress when the dishwasher was dropped at a certain orientation. The return hose separated slightly from the sump, causing leaks during the initial operation. In order to simulate any problems during delivery and installation, the drop test is performed to evaluate the robustness of the dishwashers.

Solution: Design engineers trialed P-80® Grip-it as a replacement for the current lubricant. Grip-it’s dual properties of lubrication and adhesion offered a better outcome.

Grip-it passed the prototype test phase and was moved into production. Assembly workers commented on Grip-it’s superior assembly lubrication over the previous product. Also, Grip-it provided detergency, which cleaned the hose assembly and adjacent areas. Most significantly, the slightly tacky residue of dried Grip-it increased the removal force to 33 pounds, which was found to withstand the tangential stress subjected during the drop test.

All P-80® products are manufactured in the USA by International Products Corporation (IPC) and are readily available worldwide through a network of global distributors. Contact IPC for a free P-80® sample kit by visiting http://www.ipcol.com or email sample@ipcol.com.  P-80® is available for purchase online at http://www.ipcol.com.

P-80® Lubricants are Ideal for Appliance Assembly and Service

Dishwashers, washers and dryers, refrigerators, mixers, blenders, and many other appliances have rubber or soft plastic components such as hoses, O-rings, seals, grommets, plugs and more. The slip resistance of these parts makes assembly difficult. P-80® temporary rubber assembly lubricants significantly reduce friction helping these parts slide easily into place.group-p-80

P-80® lubricants are water-based, and do not contain alcohol or petroleum distillates so they will not cause rubber to dry out or harden. P-80® does not contain silicone or other persistent ingredients, so once dry you have a tight fitting part.

P-80® lubkitchenappliancesricants come in a broad range of formulas and sizes to meet all appliance assembly needs. Two, P-80® Emulsion IFC and P-80® THIX IFC, are approved for Incidental Food Contact applications (meeting FDA regulation 21 CFR 178.3570) and are registered with NSF as USDA H1 lubricants.

Red and black Electric Blender photographed straight on. The base of the blender is red with black buttons. It has a glass container, with a glass handle, and a black plastic top. The buttons on the base, serve to adjust different speeds. The blender is useful for mixing chopped food, or alcoholic drinks. You can pur?e all different kinds of food. The blender is highly reflective and shows highlights on the left and right side. The subject is a cut out, and is isolated on a white background. The image is in full focus, from the front to the back, achieved by stacking multiple exposures.

P-80 lubricants enable rubber parts to slide easily into place with minimal force. Kitchen ApplianceOnce dry, P-80 stops lubricating and parts remain in place, resulting in a tight fit. Since P-80 does not contain silicon or any other persistent ingredients, once dry the slipping action goes away.

Advantages of using P-80 lubricants:

  • Reduces force required for installation
  • Increases production rates
  • Reduces part breakage and rejects
  • Allows for closer fitting part design
  • Reduces risk of musculoskeletal and slippage related injuries
  • Safe and Ready-to-Use

Comparison of P-80 Formulas
comparison-of-p-80-formulas

Read IPC Case Study: dishwasher drop-test.

Contact International Products Corporation for assistance in determining which P-80® formula will best serve your needs. For sales and service in the U.S. call our ISO:9001 certified manufacturing facility at 609-386-8770 or email mkt@ipcol.com. For sales and service in Europe, call 44-0208-857-5678 or email saleseurope@ipcol.com. You may also visit our website at http://www.ipcol.com.

CASE STUDY: P-80® THIX RUBBER LUBRICANT GEL

P-80 THIX Rubber Lubricant Gel Solves many Hydraulic Line Assembly Problems

Accomplishments:

  1. Eliminate false positive hydraulic leaks and contamination.
  2. Allow easier thread starts and aligned joint assemblies; achieve torque specification.

Additional Benefits:

  1. Non-hazardous product
  2. Biodegradable
  3. Temporary lubrication technology
  4. Rubber-compatible, thixotropic & synthetic

Challenges:
A crane manufacturer experienced problems with hydraulic systems; namely, contamination, rolled O-rings, leaks, and line shut-downs because of many false-positive leak detections. Multiple petroleum-based lubricants were used over the years for the assembly of hydraulic hoses and thread starts. While these lubricants eased the assembly of the hydraulic lines and facilitated thread starts, the lubricants, if not applied meticulously, slowed production, increased cost of quality, and increased rework. Over-application of these lubricants caused residue to remain in and around hydraulic lines attracting dirt, contaminating hydraulic systems, fluorescing brightly during black light leak inspections – leading to false positive results, and reducing installation torque over time. When used sparingly, the lubricants caused leaks from rough thread starts, rolled O-rings, friction-related damage, misaligned parts, and low installation torques.

Solution:
A cross-functional leak-prevention team of design and material engineers and hydraulic line assemblers trialed P-80 THIX Rubber Lubricant Gel for assembly of hydraulic lines and coating of threads for wet torque starts. Since THIX is a water-based emulsified thixotropic gel, the volume applied was not critical. Once applied, THIX remained in place regardless of the part’s orientation. The gel as a whole reduced assembly friction by 70% thereby eliminating rolled O-rings and misaligned parts. Installation torques was achieved consistently. After assembly, THIX begins to evaporate and loses its lubrication – leaving at most a negligible residue, which will not attract dirt or contaminate the hydraulic system, will not fluoresce, and cannot reduce torque over time.

THIX biodegrades over time, and because it is not petroleum-based, will not swell or soften elastomers. THIX is made from plant-derived, renewable resources and is non-hazardous based on lab tests.

The crane manufacturer experienced an immediate improvement in cost of quality and on-time delivery metrics. THIX has been implemented throughout the entire assembly floor and is currently being trialed at other locations worldwide.

All P-80 products are manufactured in the USA by International Products Corporation (IPC) and are readily available worldwide through a network of global distributors.
Contact IPC for a free P-80® sample kit by visiting www.ipcol.com or email sample@ipcol.com.  P-80 is available for purchase online at www.ipcol.com.

« Older Entries