The Importance of Consistent Seal Water Flow
Pump seal water provides essential lubrication between seal faces and removes impurities, dissipates frictional heat, and facilitates a positive pressure barrier that prevents process fluid contamination. Pump seal water systems require precise, consistent flow rates regardless of pressure fluctuations to function effectively.
Without proper flow control, facilities face costly seal failures, unplanned downtime, and excessive water consumption.
Common Flow Control Problems
Insufficient Flow Leads to Premature Failures
When seal water flow becomes inadequate or inconsistent, problems develop quickly. Insufficient lubrication causes increased friction and wear, while poor cooling allows temperatures to exceed material limits. This results in seal face damage, thermal distortion, and eventual leakage.
The economic impact is significant - emergency seal replacements cost thousands in parts and labor, while unplanned downtime affects production and profitability.
Excessive Flow Wastes Resources
The inverse of inadequate flow is also problematic. Many facilities operate with higher than needed flow rates because they either lack the ability to properly control the flow or take a more is better approach, leading to flow rates of 5-10 GPM when only 1-2 GPM may be required. This wastes substantial amounts of treated water and increases operating costs.
This excess flow also overloads water treatment systems, circulation pumps, and cooling equipment, resulting in unnecessary energy consumption and higher utility bills.
How the Kobold REG Provides the Solution
The Kobold REG flow control valve maintains precise flow rates automatically, regardless of upstream pressure changes. Unlike traditional pressure-reducing valves or manual throttling valves, the REG eliminates the need for constant adjustments or complex control systems
Key Features:
- Differential pressure operation with internal spring-loaded mechanism
- Automatic adjustment to maintain preset flow rates
- Available in flow rates from 0.13 to 10.56 GPM
- Compact construction in stainless steel or brass for durability
- Simple installation with standard pipe connections
When system pressure increases, the valve restricts flow to maintain the target rate. When pressure decreases, it opens wider to compensate. This automatic regulation ensures consistent performance without manual intervention.
Return on Investment Analysis
Reduced Maintenance and Downtime Costs
Proper seal water flow extends seal life and reduces replacement frequency. Emergency seal replacements typically require multiple hours of downtime for pump shutdown, disassembly, repair, and restart procedures.
With consistent flow control, seal replacements can occur during scheduled maintenance rather than emergency situations, eliminating costly unplanned downtime. The REG often pays for itself by preventing just one emergency seal failure annually.
Simplified Operation
Traditional installations often either involve complex automated systems or tedious manual solutions that require technicians to manually adjust throttling valves, often without flow measurement to verify proper settings. This creates variability between installations and uncertainty about actual flow rates.
The REG provides guaranteed flow performance without adjustment requirements. Installation requires only standard pipe connections with no electrical connections, control signals, or calibration procedures needed.
Significant Water Conservation
Facilities commonly over-supply seal water to ensure adequate flow, wasting substantial quantities of treated water. A single pump using an excess of 5 GPM of seal water in continuous operation will waste over 2.6 million gallons of water annually.
At typical water costs, this waste can cost thousands of dollars per year per pump in water and treatment expenses alone. The REG eliminates this waste by delivering exactly the required flow rate.
Water Savings Calculator
Determine your potential savings with optimized flow control using this cost savings calculator:
Facility Operating Parameters
Pump Seal Water Flow Analysis
| Pump ID | Current Flow (GPM) | Recommended Flow (GPM) | Flow Reduction (GPM) |
|---|
Annual Savings Results
Quick Reference - Typical Recommended Flows
- Single mechanical seal: 1.0 GPM
- Dual mechanical seal: 1.5-2.0 GPM
- High temperature applications: 2.0-3.0 GPM
- Abrasive service: 2.0-2.5 GPM
Export Results
Summary
The Kobold REG flow control valve transforms pump seal water systems from maintenance-intensive installations into reliable, self-regulating systems. The combination of extended seal life, reduced downtime, water conservation, and simplified maintenance provides a compelling return on investment with rapid payback.
For facilities looking to optimize pump reliability while reducing operating costs, the REG delivers consistent performance with minimal maintenance requirements. The automatic flow regulation eliminates variability and provides confidence that seal water systems perform as designed.
