Unobtrusive Data Acquisition

We will travel to your site and, without any interruption to production, make accurate measurements of system flow, pressure, power consumption, density, viscosity, pipe condition and more.

Accurate Hydraulic Modelling

We will use our measured data to create a hydraulic model which accurately simulates your system. This will be calibrated and then validated for full confidence.

Methodical Power Analysis

Using the validated model, we will investigate various changes, and perform a comprehensive analysis to identify the most effective power savings for your system.

Pump & Flow Cutting your pumping costs

Pumps are at the heart of many process streams, but because of their relatively low CAPEX and OPEX they are oftentimes overlooked as plant managers look to focus on bigger ticket items for cost savings. However many sites were constructed before accurate 3D design tools were available, and consequently the pumps were sized only approximately, based on estimates of elevations and frictional losses. This inefficiency is compounded by that fact that the internal surfaces has generally become much rougher with age due to scale, wear or corrosion . These losses are small, but they have a cumulative effect across the plant, and over the life of the asset they can amount to considerable cost.

See how much can be saved by improving the efficiency of a single pump:

Pump & Flow are equipped to accurately measure, model and validate a system, and this is the differentiator which enables us to make objective recommendations with a high degree of certainty. Before any suggestions are made the model is vigorously validated and proven to be accurate, and we use the most reputable instrument brands for full assurance. Without any interruption to operations, we will:

  • Measure the power consumption of the pump motor
  • Measure the run lengths and elevation changes through the system
  • Measure the fluid properties, including flow rate, pressure, temperature, density and viscosity of the process stream, and
  • Measure the surface roughness of the pipe

Based on this data we will analyse the system, validate our baseline model and then seek out changes which will reduce your power consumption. We’ll look at the effect of changing impellers, pump, motor, and line size. These suggestions will be presented in a report for your consideration. Should you decide to carry out any of the suggestions presented, we will take a percentage of the savings made. Pump & Flow will not make any promises before visiting your site – the process is risk free, with our fee coming entirely out of the cost savings.

Pump & Flow do their best to offer services in an expeditious manner so as to keep client costs low. In return, our technicians need to be able to get in and obtain measurements without any undue delay.

Access to the plant

In order to accurately model your plant’s systems Pump & Flow needs good, unhindered access to the plant for one or two technicians to take measurements. Unless we indicate otherwise our analysis services can be performed without interrupting the system’s operations, but it is necessary for the plant manager to be aware of our activities. In particular:

Consumed motor power

A Pump & Flow technician will need to remove a terminal box cover from the pump motors while the pump is in normal operation in order to measure the instantaneous current. The data logged during this measurement forms the basis of the power consumed, and it is the benchmark by which any gains will be measured.

Pipe Work

Using a reflectorless total station the technician will work along the length of the pipe and take accurate measurements in three axes of each fitting in the system. The technician will need access along with wherever the pipe
system goes.

Surface roughness

The internal surface roughness of pipework has an outsized effect on the accuracy of analysis, and given the multitude of grades of material, age of pipe, and possible service fluids, the only surefire method of analysis is to physically measure the absolute surface roughness. This possible by taking a hot tap coupon. Pump & Flow will identify a suitable location and will install a bolted tapping saddle and shut-off valve suitable for the pressure and service of the system, before drilling out the coupon and installing a temporary datalogger. At the same time, a fluid sample will be taken. Once the data has been collected the logger will be removed and the valved plugged or capped.

Results are only possible if the plant manager (or representative) agrees to provide Pump & Flow with the access required to perform these measurements. Pump & Flow has detailed standard operating procedures which cover their on-site works in detail, and these will be provided to the plant manager well in advance to provide assurance that all work will be done in a safe manner, with adequate controls in place for all reasonable risks. Pump & Flow will request the plant manager (or representative) to review and approve these procedures prior to undertaking any site work.

Furthermore, as the site-based measurements are obtained a comprehensive QA/QC checksheet is compiled for full traceability. The site will be issued a copy of this document for their records.

With over 11 years of work history within Australia’s resources industry Pump & Flow has the tools, knowledge and experience to identify improvements in your pump systems. We are offering to visit your site and find savings.

Contact Us

We aim to provide responsive service. Please contact us and
we will do our best to address your query: