The Role of Stator Design in Progressive Cavity Pumps
Progressive cavity pumps find a varied range of applications in different markets such as oil & gas, chemical processing, food and beverages, pharma, and more. The stator is one of the most important progressive cavity pump components. Its design and material play a huge role in its functionality.
In this article, we will understand how this small part of the progressive cavity dosing pumps works. We will also discuss the design in detail to understand its role and importance in the anatomy of the pump.
What a stator is and how it works?
The progressive cavity pump relies on the stator and the rotor to move fluid through the pump. Stator is a stationary casing that is made with two different materials. The primary role of a stator is to provide a leak-proof passageway for the fluid to flow through during pumping.
The inside of the stator has a helical design complementing the helical rotor. The rotor turns, moving in eccentric circles. This creates leak-proof chambers between the two core components. The fluid moves in from the inlet and these chambers change with the rotor’s movement along the stator, pushing the fluid out of the outlet.
The interaction between the stator and rotor enables the pumping of fluids of varying viscosities with little wear and tear. Many industrial uses rely on this, including progressive cavity pump oil and gas operations.
Stator Design and Material
The stator design and material plays an important part in its functionality. It determines flexibility and durability during continuous operation under different environments.
The inside of the stators is often made from corrosion-resistant materials that can pump corrosive fluids. It is usually made from elastomers, suiting specific operational needs. It can be natural rubber, synthetic rubber, or other materials that resist chemicals, high temperature, and abrasive use. These materials are particularly used in food grade progressive cavity pumps, such as Hydro Prokav’s KX-F Series.
The stator is designed carefully to work in conjunction with the rotor smoothly. It complements the helical (screw-like) structure of the rotor. The precision in design ensures the fluids get pumped at a consistent rate as the rotor rotates. This rate is proportional to the rotation speed, which is necessary for accurate dosing and metering.
The precision of the design also determines the clearance between the rotor and the stator. The lesser the clearance, the slower the mechanical wear. However, it is important that the pumped fluid offers some sort of lubrication between the two progressive cavity pump components to protect against friction and wear. This extends the lifespan of the parts, eases progressive cavity pump maintenance, and reduces long-term operational costs.
Stator Damage and Maintenance
It’s normal for a pump’s stator to wear out over time naturally. It is one of the most frequently replaced components.
This happens due to the ongoing friction between the stator and the rotor from the rotational movement. You might consider replacing the stator when you note the following damages:
- The gap between stator and rotor increases over time, decreasing efficiency
- The pumping gets slower and there’s a lack of consistent outflow
- The pressure decreases or there’s no pressure at all
- The pump makes weird noises or there’s unusual matter in the chambers
- The inner lining of the stator comes off
The pump stators, like car tires, need to be changed promptly. The amount of time a pump stator lasts depends on the stator lining quality. Under typical pumping circumstances, it is recommended that you change the pump stator once every year or two.
If not chosen correctly, the inner lining could be more susceptible to wear and tear, corrosion, and rapid aging. Under extreme circumstances, the liner might partially tear or even come off the outer casing. Therefore, the versatility of the available stator materials and their fundamental characteristics must be understood.
Conclusion
You should now have a better idea of how the stator construction and material affect the pump's performance and lifespan. When choosing a progressive cavity pump, it is crucial to consider the stator specifications. For optimal performance with little maintenance, use materials that align with your application needs.
Hydro Prokav offers a variety of progressive cavity pumps to suit various industrial needs. To guarantee top performance to their happy customers. Contact us today to understand how our pumps can elevate your operations.