Mines and industry rely on critical high pressure pump technology to keep operations safe and efficient, which makes rigorous testing of this equipment an essential part of the manufacturing process.
According to Kathryn Poke, director of engineering at RMI Pressure Systems, dedicated test cells in the company’s Manchester production facility support a range of technical tests to ensure final product quality. RMI Pressure Systems is a global leader in high pressure and high volume fluid pumping stations, with over a century’s experience in designing, manufacturing and supporting this technology. With a primary manufacturing facility in the UK, the company has operations in China, the US, India and Australia – supporting equipment in countries around the globe.
Poke said that RMI Pressure Systems’ quality and testing regime means that new equipment and components can be put through as much as two million pump cycles – over periods of up to 160 hours – to prove their integrity.
“In robust and continuous applications such as longwall coal mining, our customers rely on our high pressure reciprocating pumps to deliver optimal uptime and safety,” she said. “Similarly, our steel industry customers look for quality and reliability in de-scaling and forging applications.”
In these demanding and often hazardous environments, pump pressures can reach 350 to 400 bar – making any leaks or defects potentially disastrous. She highlighted that RMI Pressure Systems’ meticulous testing regime has been critical in building the company’s quality reputation for over a century.
Dedicated test cells in RMI Pressure System’s production facility ensures final product quality
“Before delivery, all of our equipment is put through its paces in our test cells,” she explained. “These well-resourced facilities measure and record temperatures, pressures, speeds and other indicators – generating data that is carefully reviewed and analysed by our engineering team.”
She emphasised that the test cells run alongside the company’s manufacturing processes, which are accredited in terms ISO9001 quality standards. This ensures that the extended periods of testing do not compromise RMI’s production rates. The test facility can accommodate three RMI high pressure pumps at a time.
“This means that our customers are confident that RMI equipment is ready to go when it is installed and commissioned on site,” said Poke. “There is no run-in time or bedding down to be done, so the pumps’ contribution to productivity and uptime will be immediate.”
Experts from RMI Pressure Systems are available to assist with installing and commissioning the equipment, giving customers peace of mind and ensuring optimal performance. The company’s manufacturing quality is also enhanced by its careful selection of suppliers and components; these are chosen on their excellence, and regular quality assurance processes are applied. Cycle testing of components is also conducted to ensure a quality finished product.
“Our inspection team tests new components extensively against the conformance criteria before giving it the thumbs up,” she said. “Staying up to date with technology allows us to improve designs, software and materials of construction wherever possible; each improvement, though, needs to be thoroughly tested before we introduce it to the market.”
High pressure pumps are often subjected to very demanding applications in mining, steel and many other industries – making their careful design and selection vital to safety, reliability and performance.
“In addition to exacting engineering standards and technical criteria, there is also the need for a stringent and often lengthy testing regime before equipment is dispatched and installed for customer use,” according to Kathryn Poke, RMI Pressure Systems’ general manager for Europe, the Middle East and Africa (EMEA).
As a global leader in high pressure reciprocating pumps, RMI Pressure Systems has a rigorous understanding of the critical functions essential to the reliability of these systems. Poke highlights some of the key ways to optimise pump design and selection.
Choose safety first
“Safety and reliability are critical factors to consider, including safety features such as a safety relief valve,” she says. “This valve protects against a ‘dead head’ situation in which the system demand for flow has stopped, causing the pressure to rise instantly.”
She says the safety valve should be designed to allow the entire pump capacity to flow, while the opening point should be set at 10% above the operating pressure. Also, the pipework associated with the safety relief valve should be properly sized to ensure adequate flow conditions.
“At RMI, we include a number of safety circuits to prevent a potential dead head condition,” she explains. “This includes a pump safety relief valve, and an unloading valve, or valve filters, which protect the pump against a potential hydraulic lock.”
Sensing and sealing
There are also oil temperature and pressure sensing circuits, as well as motor overload monitoring. These systems can indicate a potential issue with the system, allowing the pump to be stopped before any damage is caused.
“The sealing system of a pump is an equally important contributor to safety, and also enhances overall performance and reliability,” says Poke. “For high pressure reciprocating pumps like RMI manufactures, the task is typically performed by the stuffing box; this contains packing and lubricant in various configurations, depending on the application.”
As a service item, this packing should be able to be replaced without too much interference with the main pump assembly – so the pump design should accommodate this requirement.
Best use of energy
“Efficiency is also a priority for pump owners and operators, and reciprocating pumps offer important benefits in this regard as their design offers greater mechanical efficiency,” she says. “This intrinsic feature means that a smaller prime mover can be employed to drive the pump, which will mean the consumption of less energy.”
Not only will the careful selection and matching of the correct motor to the pumping system enable a more efficient combination, but it will also help achieve a lower total cost of ownership (TCO) for the customer.
“Variable speed technology effectively reduces energy consumption by allowing the pump to idle in a standby condition,” she says. “At the same time, it can still return to full service quickly and efficiently when required.”
This provides a valuable alternative to other options such as the complex by-pass, drain or accumulator systems; it allows the pump to run without generating further pressure, while also allowing system flow and pressure to be maintained as needed.
Trust in experience
“With over 100 years of experience in this field, at RMI we understand the demands of high pressure pumping applications and are proud of the reputation for reliability that we enjoy in global markets,” concludes Poke.
Getting the benefit
• Relief valves for safe operation
• Sensors to monitor for early warning signs
• Quality seals for performance and reliability
• Reciprocating pumps offer high efficiencies
• Variable speed technology cuts energy consumption
When a steel rolling mill in Italy was looking to enhance the quality of its product while improving overall efficiency, it turned to a partnership of metallurgical plant solutions company Primetals Technologies and high-pressure pump specialist RMI Pressure Systems.
The mill decided to invest in new descaling equipment – with a view to raising quality standards while lowering overall energy and water costs. According to Kathryn Poke, RMI’s general manager for Europe, the Middle East and Africa (EMEA), the company designed a bespoke solution based on its established Trimax Series of reciprocating plunger pumps.
RMI Pressure Systems designed a bespoke solution based on its established Trimax Series of reciprocating plunger pumps
“Engineered to order like all our solutions, we designed the system to suit the project requirements,” said Poke. “With the Trimax pump at its heart, the specialised system for the mill included controls, nozzles and headers to ensure reliable and efficient operation.”
RMI was required to provide a pump which could deliver hydraulic power at multiple pressures, using a variable speed drive and engineered nozzles. The result was a system capable of producing flow rates from 50 up to 670 litres per minute, at pressures up to 1,000 bar.
RMI Pressure Systems helps steel manufacturers improve overall efficiency in steel descaling operations (Image: Primetals Technologies)
“The technical design of descaling equipment is an exact science,” she explained. “This requires precision nozzle design and high hydraulic pressures calculated to deliver the best descaling results for a variety of steel variants, at minimum cost and maximum efficiency.”
The variable speed drive and engineered nozzles ensured that the system delivered controlled hydraulic pressure and precision impact, while consuming less energy and water. The system was performance-tested, confirming its robust design and manufacture – which would underpin its reliability and uptime. The lower installation and maintenance costs resulted in a payback period of less than two years.
RMI managing director Joe Keenan highlighted the value for customers of pump manufacturers moving beyond a focus on discreet products and into the systems space.
“Customers are increasingly looking for solutions and not just products,” said Keenan. “This contract illustrates how RMI’s custom-design capability allows us to build fit-for-purpose solutions with our pumps as a central component.”
He noted that the trend is toward OEMs gaining more specialised knowledge about how pumps are applied in specific applications, so that they can augment their offerings with other componentry, accessories and technology. This allows the customer to source more of their operational equipment from a single supplier, reducing the risk and resources associated with integrating and maintaining these different elements in-house.
RMI Pressure Systems is a global leader in high pressure and high volume fluid pumping stations, with over a century’s experience in designing, manufacturing and supporting this technology. With a product development and manufacturing hub in Manchester, England, RMI Pressure Systems has operations in the US, China, India and Australia. It also serves markets in Europe, the Middle East and Africa. Its in-house research and development capability drives the continuous innovation of its products and solutions.
RMI Pressure Systems Shines at CCME 2023 Showcasing Shanghai Facilities and MA Certification in the Heart of China’s Dynamic Coal Mining Sector
Highlighting its new Shanghai facilities and MA certification, reciprocating pump specialist RMI Pressure Systems rubbed shoulders with industry decision-makers at the recent China Coal and Mining Expo (CCME) 2023 in Beijing.
Sabrina Zhang, Director for Aftermarket Sales, Services and RMI Operations in China
According to Sabrina Zhang, Director for Aftermarket Sales, Services and RMI Operations in China, this year’s event reflected a busy and competitive coal mining sector. Zhang said visitors to the company’s exhibition booth responded positively to this year’s approval by the MA Centre of RMI’s local manufacturing facility in Shanghai.
“The CCME delegates we spoke to were pleased to hear more about our local facilities, and looked forward to the continued roll-out of our localisation strategy,” she said. “We are confident that this will further strengthen our established reputation in China for quality and reliability – by improving our turnaround time and competitiveness.”
With the approval by the MA Centre, responsible for certifying mining product safety, RMI’s local manufacturing facility in Shanghai is now able to produce 15 different models of precision-built high-pressure pumps.
Joining the RMI team at CCME was Huw Dodds, RMI’s director for sales and service in Australia, who noted the strong interest in digitisation and automation in all aspects of underground mining. The four-day event showcased a wide range of mining fields from electromechanical and power to smart mining, instrumentation and processing. Also engaging their visitors at the RMI stand were staff members from the Beijing and Shanghai offices, as well as the company’s Inner-Mongolia-based service manager.
With its headquarters and factory in Manchester, United Kingdom, RMI exhibited with other members of the British industry association Abmec – reflecting the strong global appeal of the CCME. Dodds said that the mining sector in China is served by a strong local and international production base, which was constantly evolving to embrace the latest technologies.
By: Joe Keenan, Global Managing Director: Industrial Fluid Flow Solutions at RMI Pressure Systems
As players in the highly competitive global pump sector move from a ‘product’ to a ‘system’ focus to differentiate themselves, the most successful efforts are likely to be those that impact directly on customer’s cost imperatives and their environmental, social and governance (ESG) priorities.
The global industrial pumps market – which by some estimates is worth around US$70 billion a year – continues to grow rapidly, at an annual compound rate of 4-6%. On the average industrial site, it is likely that pumps account for some 30% of the total energy consumed. At the same time, it is acknowledged that the vast majority of pumps operate at low efficiencies – wasting money and generating unnecessary volumes of carbon dioxide.
Addressing these energy inefficiencies should therefore be a priority for the growing pump sector, as such initiatives feed strategically into customers’ commercial and ESG imperatives. An important way of doing this can be seen in the shift away from a purely product offering – and towards broader system-based solutions for customers. Such a shift also presents opportunities for brand differentiation, in a market that has become increasingly commoditised.
Pump designers and manufacturers must respond to customers’ pressing needs, such as equipment longevity and reliability.
In pursuing this differentiation, designers and manufacturers of pumps need to respond to their customers’ pressing needs in their specific applications. A key differentiator, for instance, is for equipment to last longer and perform more reliably, which for many customers is a vital bottom-line requirement.
Climate change and global conflicts
With climate change and the current geopolitical instability, though, have come other important prerogatives that define value for customers – especially those in energy-intensive sectors such as mining and steelmaking. For industries like these, ESG is now becoming a central element in strategy and branding, demanding more efficient use of energy in production – especially as gas and power costs surge in the wake of the Ukraine conflict.
Many large customers are therefore looking to reduce their carbon footprint and operating costs by using less energy, while at the same time also conserving water as an increasingly precious natural resource. Responding to these needs should therefore be front-of-mind as pump specialists embrace system thinking to enhance their offerings.
Into the systems space
While pump OEMs must continuously improve technical aspects of their equipment, there are invariably diminishing returns on these gradual enhancements. The more comprehensive and significant trend is beyond the realm of the product, and into the systems space. Here, the pump is one component among others within a system that aims to solve multiple customer requirements, not just one.
By way of illustration, a pump user would traditionally procure a pump for a certain purpose, and would need the in-house expertise and infrastructure to install, monitor, maintain and service that equipment. This requires specialised knowledge about how that pump is applied in that specific application – or system – in order to ensure that the pump delivers the value required to warrant its purchase price.
A market shift occurs when a pump supplier begins to augment its offering with the other components or accessories that the customer has previously had to procure themselves. It could even occur through corporate acquisitions of upstream or downstream ‘phases’ of production, allowing the customer to source more of their operational equipment from a single supplier.
Lessons from EVs
The significance of system offerings as a disruptive strategy was recently highlighted in the process of developing and marketing electric vehicles (EVs). With innovative battery technology as the enabling innovation behind the EV revolution, what we have essentially witnessed is a vehicle being constructed as a ‘system’ around a battery. This process has not only provided customers with a differentiated product but has created a new trajectory for the motor industry.
The recent experience of the burgeoning EV industry holds some nuggets of wisdom for all sectors, not least the well-established pump business. Two insights stand out for those companies wanting to grow their offerings from stand-alone products to systems. The first is focus: businesses can seldom be good at everything, so they need to decide where exactly their energies and resources are best directed. The second is building the knowledge base: a system solution invariably means moving downstream into aspects of the customers’ operation for which they – or another supplier – were traditionally responsible.
More responsibility
This means learning more about what the customer already knows, to essentially assume more responsibility for their process. The next important strategy is to harness the power of technology for this new system, to improve monitoring, leverage operational data, predict maintenance requirements and raise uptime levels. In the pump sector, there is significant progress here and potential to do more, including the increased use of variable speed drives to conserve both energy and water.
For those companies with the insights and resources to successfully move forward on this basis, there is considerable benefit. They move themselves into a less crowded trading space, as the barriers to entry are likely to prevent most of their previous competitors from following. Most importantly, it situates the firm in a different relationship to customers – where the conversation moves away from products and their features, to outcomes and their value.
Collaboration
For the customer, the conversation is now elevated to a level where their key performance indicators (KPIs) – including compliance with ESG standards – can be discussed. The supplier becomes the service provider, and takes an active role in helping the customer achieve these KPIs – through systems that include pumping equipment but are judged – and sold – on different terms.
In this sense, the strategic shift into the realm of systems and solutions must keep pace with the changing imperatives that drive customer decision making, turning the supplier relationship into even more of an ongoing collaboration.
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