At the heart of all spray operations in your mill, is the spray nozzle. It is the component that determines performance in moisturizing, cleaning, lubricating, edge trimming, bleaching, knock-off, gluing and dozens of other applications . Worn nozzles can raise water consumption drastically.
The cost of using nozzles worn by only 15% in your mill can increase by thousands of Rands.
Centrifugal pumps: Monitor the readings of your flow meter to check for increases in flow.
Use a calibration vessel to measure the flow of a nozzle for a specific time at a specific pressure.
Compare the readings with the manufacturers catalogue or compare them with the same tests conducted on a new nozzle.
Positive displacement pumps: In applications using positive displacement pumps, which provide the same capacity regardless of pressure, the spraying pressure will decrease as the nozzle orifice enlarges. Lower spray velocities and spray impact will result.
Pressure at showers and nozzles
Centrifugal pumps: Monitor for increases in volumes of liquid sprayed. The pressure of the spray could decrease.
Positive displacement pumps: Monitor gauges to detect any drop in pressure and reduction on the impact on surfaces sprayed. The volume of the sprayed liquid may remain the same. Also monitor for any increases in pressure which could be caused by blocked nozzles.
Check for premature wear of the felt or any other related problems. In applications with centrifugal-type pumps, impact may actually increase because of the increased flow through the nozzle.
Visually inspect the spray pattern to detect any changes in uniformity.
Streaks and heavier flows in the centre of the pattern, accompanied by a decrease in the effective spray angle coverage typify deterioration.
Measure the width of the spray over the surface sprayed.
If the nozzle wears gradually, you may not be able to detect any changes until a significant increase of flow is evident.