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Colleagues, during the commissioning of skid-mounted equipment for a project recently, I encountered an issue where the flow rate kept dropping after the centrifugal pump started up. I would appreciate it if you could help analyze this problem. The process is as shown in the CAD diagram: the expansion tank is located at a higher position, with a capacity of around 1.5 m3, while the centrifugal pump is situated at a lower position. Its flow rate is 160 cubic meters per hour, and its head is 20 meters. The outlet of the centrifugal pump enters the shell side of the tube heat exchanger, where it is used to exchange heat with other fluids flowing in the tube side. After exiting the tube heat exchanger, the fluid goes into the plate-fin heat exchanger, and finally returns to the expansion tank; the on-site equipment is shown in the other two diagrams. The problem now is: 1) Since no valve is installed at the outlet of the centrifugal pump, only a butterfly valve is installed at the outlet of the shell-and-tube heat exchanger, before it enters the plate-fin heat exchanger; therefore, before starting the pump (after filling it with fluid), I first closed this valve, and at that time the pressure indicated by the pressure gauge was around 0.35 Mpa. After the valve was fully opened, the flow rate rose to 80 cubic meters per hour, but it began to decrease gradually, eventually dropping to 4 cubic meters per hour, with a pressure of 0.05 Mpa. 2) Initially, I suspected that there was a problem with the electromagnetic flow meter; therefore, to verify the discharge flow rate, I opened the outlet leading back to the expansion tank, and found that the flow rate indeed decreased and was below the optimal level. 3) There is a conical filter installed in the pipeline; I removed it and cleaned it as well, but that did not solve the problem. 4) I once again considered whether the flow rate of the centrifugal pump was too high, the volume of the expansion tank was too small, and the pumping time was too short, all of which could lead to cavitation. So I tried to reduce the valve opening and lower the flow rate in the pipeline, in an attempt to find a stable equilibrium point. However, the butterfly valve does not have strong regulating capabilities; if the valve opening is too small, the flow rate is too low, and while increasing the opening slightly raises the flow rate, it starts to drop again very quickly. 5) At the same time, I wonder if the head pressure is too low; the pressure drop across the plate-fin heat exchanger is relatively high. Therefore, I plan to disconnect the plate-fin heat exchanger tomorrow and have the fluid flow directly from the tube heat exchanger back to the expansion tank, in order to verify whether the flow rate will decrease further. Regarding the above debugging process, I would appreciate it if colleagues could analyze what other factors might be causing the current situation and share their insights
It seems that the volume of the system is larger than that of the expansion tank, so it’s not possible to fill the entire system; you might try adding more water.
The flow rate should increase when the pressure decreases, but it also decreased; the only thing that comes to mind is that the pump’s speed has reduced.
Is there always a lot of water in the expansion tank? Try setting up a circuit for circulation and create a branch.
What is the size of the water tank? Could it be that there isn’t enough water to fill the entire system, preventing the pump from drawing water in?
Please measure the temperature; if it is too high, vaporization will occur at the inlet, leading to cavitation
Cavitation is still a possibility; as the flow rate decreases, the temperature rises, creating a vicious cycle
There is no frequency conversion, and ordinary pumps don’t come with adjustable reducers either. How can the speed be changed? Do you have any basic knowledge on this?
1. A drop in pump outlet pressure and flow rate indicates that the water inflow has indeed decreased; 2. How much has the water level in the tank changed, and has there been any change in temperature? ; 3. Does the pump have variable frequency control, and is it linked to the water level in the tank for automatic adjustment? ;
It seems that the valve opening is too large; this is an operational issue. It is recommended to control it according to the pump’s rated current and gradually increase the valve opening, so as to keep the pressure within the pump’s head range and prevent it from dropping. In this way, once the entire system is working properly, just make a final adjustment. At that point, the outlet valve does not necessarily need to be fully open; its opening degree is such that the rated current remains below the specified limit and the head (exit pressure) stays above the design parameters. It’s incorrect to assume that the pump can be operated at full capacity right from the start.