| YEARBOOK 2014 | 20th VOLUME

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ingenieur verlag nagelUhlandstraße 1D-72631 AichtalGERMANY

PUMPS AND SYSTEMSMADE IN EUROPE

Andritz Ritz, Germany

Beinlich, Germany

Bungartz, Germany

Edur, Germany

Flotronic, United Kingdom

Fuji Electric Europe, Germany

Gather, Germany

Grundfos, Denmark

Hanning, Germany

Herborner, Germany

HNP Mikrosysteme, Germany

Homa, Germany

Klaus Union, Germany

Knoll, Germany

Kostal, Germany

KSB, Germany

KTR, Germany

Leistritz, Germany

Lewa, Germany

Lutz-Jesco, Germany

Motive, Italy

Netzsch Pumps & Systems,Germany

Pfeiffer Vacuum, Germany

Prominent, Germany

Renner, Germany

Schmalenberger, Germany

Sero, Germany

Sterling Sihi, Germany

Global

Optimized motors and hydraulics

Optimized motors and hydraulics

The new EffTec Series from Homa offers highest overall efficiency in wastewater disposal – page 28

www.delta-p-online.com

www.pumps-directory.com

A P A S S I O N F O R P E R F E C T I O N

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Vacuum solutions from a single source

PUMPTECHNOLOGY

Delta p – The international MAGAZINE ofGlobalCONTENTS

p Global 2014 – 20TH YEAR

Andritz Ritz, GermanyWorld‘s largest submersible pumps . . . . . 4

Beinlich, GermanyPumps for robotic requirements of the adhesive bonding . . . . . . . . . . . . . 6

Bungartz, GermanyCavitation-free pumping . . . . . . . . . . . . . . 7

Edur, GermanyMultiphase Pumps for gassy liquids or gas enrichment. . . . . . . . . . . . . . . . . . . 10

Flotronic, United KingdomEase of maintenance and electronic rupture protection secure 3-A accreditation . . . . . . . . . . . . . 12

Fuji Electric Europe, GermanyCooling water pumping system . . . . . . . . 13

Gather, GermanyPumping a solvent mixture at 450 °C with 500 l/h . . . . . . . . . . . . . . . . 14

Grundfos, DenmarkRomanian utility company chases water leakages and energy savings . . . . 18

Hanning, GermanyState-of-the-art pump drive ensures swimming fun . . . . . . . . . . . . . . . . . . . . . . 22

Herborner, GermanySewage and vacuum pumps combined in a drainage system . . . . . . . . 25

HNP Mikrosysteme, GermanySmallest annular gear pump . . . . . . . . . . 26

Homa, GermanyHigh efficiency due to optimized motors and hydraulics . . . . . . . . . . . . . . . 28

Klaus Union, GermanyEnergy Efficient Double Volute Twin Screw Pump . . . . . . . . . . . . . . . . . . . 29

Knoll, GermanyProgressing cavity pump persuades with constructive details . . . . . . . . . . . . . . 32

p Global 2014

Kostal, GermanySmartly connect pump and motor . . . . . . 34

KSB, GermanyNew mag-drive pump for process engineering applications . . . . . . . . . . . . . 37

KTR, GermanySeparated on purpose: New design of pump shaft coupling . . . . . . . . . . . . . . 38

Leistritz, GermanyScrew pumps in tank farms . . . . . . . . . . . 39

Lewa, GermanyNew plunger pumps with drive powers of up to 800 kW . . . . . . . . . . . . . . . . . . . 44

Lutz-Jesco, GermanyDosing pump with microprocessor- controlled stepper motor drive . . . . . . . . . 45

Motive, ItalySolar panels drive pumps . . . . . . . . . . . . 47

Netzsch Pumps & Systems, GermanyWorking in extreme conditions in an African oilfield . . . . . . . . . . . . . . . . . 48

Pfeiffer Vacuum, GermanyDiamonds from the microwave . . . . . . . . 50

Prominent, GermanyProcess metering pumps for pressures of up to 630 bar . . . . . . . . . . . . . . . . . . . 52

Renner, GermanyTotal encasement for aggressive conditions . . . . . . . . . . . . . . . . . . . . . . . . . 54

Schmalenberger, GermanyNew selfpriming centrifugal pump . . . . . 55

Sero, Germany8.5 GPM @ 3,300 ft TDH and a NPSHR of 10 inches . . . . . . . . . . . . . . . 56

Sterling Sihi, GermanyOnline condition monitoring . . . . . . . . . . 58

3

p Global 20144

ANDRITZ RITZGERMANY

World’s largest submersible pumpsThe largest ever built submers-

ible motor pumps will be delivered

to China. These are three pump

units of HDM technology. The two

larger submersible pumps provide

4 megawatts (4000 kW) each and

even the smaller one 3.2 megawatts

(3200 kW).

“It was the biggest single order

in Andritz Ritz’s history,” CEO Mat-

thias Müller proudly reported. The

manufacturing of the pump units in

Schwäbisch Gmünd, Germany, was

executed within a tight delivery time

frame. There were just 12 months

between the construction and the

first test runs on the in-house test-

bed.

The pumps, each consisting of

three individual components, are 22

meters long or rather high and weigh

more than 32 tons when mounted.

The huge dimensions and high en-

gine power made special measures

necessary, such as the use of mobile

cranes and careful coordination with

the municipal utility, with respect to

the provision of electric power re-

quired for the test runs.

They must work, because it

is about human lives. In a Chinese

mine, the pumps are installed at a

depth of 900 meters, hanging freely

on the pipe. A pump unit conveys

1000 m³/h to a height of 1000 m.

The units are part of the mine’s

safety device and shall prevent that

the tunnels, in which the miners

work, are flooded.

This is made possible by the

HDM technology. Whereas HDM

stands for “Heavy Duty Mining”

and describes a technology that is

specifically designed for the harsh

conditions in mining. The double-

entry units with the patented HDM

technology are characterized by an

extremely high efficiency and long

service life and are extremely quiet.

www.andritz.com

0.75 kW to 710 kW

IP21 & IP55, DCR up to 90 kW

Built-in EMC filter for all capacities

4 PID sets

New engergy saving functions

User-friendly display

Customizable logic (mini PLC)

...and many more features!

Dedicated to water and pump applications:The book type inverter by Fuji Electric

Warranty 5 Year

Visit us on: SPS IPC Drives 2014

Nuremberg, Germany25 - 27 Nov 2014Hall 3 · Stand 308

H2O Accadueo 2014Bologna, Italy

22 - 24 Oct 2014Hall 29 · Stand B41 C42

Pollutec 2014Lyon, France

02 - 05 Dec 2014Hall 6 · Stand G86

Fuji Electric Europe GmbH · www.fujielectric-europe.com · info.inverter@fujielectric-europe.com

p Global 20146

BEINLICHGERMANY

Robotic applications are requiring

special pumps features. They need

to be small and compact on the

one hand in order not to hinder

movement even at the smallest

robot arms. On the other hand,

they are under enormous pres-

sure, since they convey media

over the entire robot arm and

need to work precisely and accu-

rately. Especially in the adhesive

bonding technology, high dosing

precision during the assembling

process is elementary, due to

the fundamental importance of

tightness of the components. As

a main function, adhesives, for ex-

ample, seal the edges of displays

and even screwed connections must

be secured in the required strength

class. For the best implementation

of difficult conveying and dosing

requirements, the application of

gear pumps is recommended. Gear

pumps are suitable for dot and bead

application and convey and dose in

exact, reproducible work steps.

Dartec® is a gear pump which

enables precise results even with

high inlet pressures. The pump is

small, compact, efficient and with its

700 grams lightweight construction,

ideal for the application on handling

devices and robots.

This pump complies with high

dosing requirements and conveys

low viscosity media (1 mPas), as

well as high viscosity media (up to

1.000.000 mPas). Especially when

dosing media with high viscosity, the

supply of pre-pressure is of tremen-

dous importance. Hence, this pump

is designed for inlet pressures of up

to 150 bar. Even for applications with

low viscosity media and a potential

simultaneous rise of operating pres-

sure up to 200 bar, the application of

this pump is suggested. Additionally,

low torques provide a good energy

balance. Efficiencies of up to 90 %

are achievable even with low viscosi-

ties.

By using different tolerance

classes, one and the same pump

type is even applicable both for

high and low viscosity media. The

encapsulated bearing minimises

dead spaces in the pump. Therefore,

the hazard of curing in downtimes

and thus a possible failure of the

machines is banned. The bearing

friction is minimal; therefore no

additional heat dissipation into the

medium is to be expected.

The dosing pump is easy to

clean, whereby this procedure is

limited to the gearbox only, since

there is no impact on the medium

with an encapsulated and self-

lubricating bearing. The application

of special coatings also leads to an

optimal technical and economical

life, which minimises any follow-up

costs for an exchange of compo-

nents.

Due to the modular system of

the DARTec® pump, different materi-

als like stainless steel or high per-

formance plastics can be used. As

it is resistant to chemicals, not only

silicons, resins or elastomers can be

conveyed in the adhesive bonding

technology but also aggressive me-

dia, amines, activators or peroxides.

www.beinlich-pumps.com

Pumps for robotic requirements of the adhesive bonding

p Global 2014 7

Cavitation-free pumpingAn outstanding criterion for all

pumps from the V-AN range is the

unique regulation characteristic.

The self-regulating centrifugal

pumps without suction capacity

can adjust independently to chang-

ing feed rates. Due to pressure

compensation the pumps have an

NPSH value close to zero and pump

cavitation-free worldwide, also

particularly dangerous media.

The V-AN principle is simple

yet brilliant at the same time: If a

medium flows into a vessel, the

liquid level rises until the feed and

discharge in the vessel are balanced

– without any type of mechanical or

electrical regulation equipment. The

supply level in the medium is self-

adjusting without any level control

depending on the actual feed rate.

In addition to the feed and discharge

nozzle, the V-AN is equipped with a

gas compensation nozzle. It is con-

nected to the gas phase of the reser-

voir. Thus, the vertical pump loses its

suction characteristics. Compared to

centrifugal pumps with normal suc-

tion characteristics, this gives the V-

AN an advantage: it has a low NPSH

value (<0.1 m, l Fig. 1) and pumps

every medium in every operating

state without cavitation.

An example: In a thermal

power station a boiling hot con-

densate in a water-steam cycle is

directed into a separator vessel and

pumped into a neutralisation vessel

after an appropriate cooling time in

the further course of the process.

The condensate is pumped by the

self-regulating VKS-AN pump. The

pump with an open impeller, which

is used here, works self-regulating.

The features of the impeller geom-

etry and the pressure compensa-

tion at the impeller contribute to

the stability. Steam, which reaches

the pump, does not cause any dam-

age. It is discharged by means of the

pressure compensation (l Fig. 2).

Contrary to a standard pump, large

size reservoirs are not needed here.

The required suction head for this

pump lies at only 0.5 to 1.5 m.

Versatile use and extremely economical

Due to the permanently cavi-

tation-free working method without

feed rate interruption, the V-AN is

also suitable for

l boiling and solids-laden

mixtures

l from pits and closed, unpres-

surised vessels such as refinery

waste tanks.

Further areas of application are:

l vacuum belt filters,

l centrifuges,

l distillation columns,

l evaporation plants and

l waste water pits,

l complete tank discharge.

In the case of the latter feed

task, tank wagons with liquid gas

(n-butane, ammonia etc.) are to be

discharged. The self-regulation of

the V-AN pump also independently

adapts to the incoming feed rate. A

pressure compensation line ensures

the automatic ventilation. The pump

can also be connected directly by the

tank wagon driver via the hose line.

The pump is flooded by opening the

valve. If the pressure line is filled,

Gas compensation

lineboiling

Nocavitation!

PD

PD

P

mFig. 2 Cavitation-free pumping:

pressure development of the V-AN

mFig. 1 Centrifugal

vertical pump V-AN

BUNGARTZGERMANY

p Global 20148

BUNGARTZGERMANY

bearings, low maintenance costs,

years of continuous trouble-free op-

erating time.

When considering the life cy-

cle costs, the low investment costs

due to savings based on low plant

construction heights and the omis-

sion of pits are not the only factors.

The low operating costs e.g. due to

efficient energy consumption and

low maintenance costs must also

be taken into consideration.

www.bungartz.de

the gas is pressed from the riser into

the upstream vessel and partly com-

pressed by the pumping pressure.

This allows the liquid to flow into the

pump. After the start the pump en-

sures the further ventilation, where-

by the gas is added to the pumping

medium. Due to pressure reduction

without cavitation, the discharge of

liquid gases is unproblematic – even

up to the boiling point.

A further aspect with the use of

the V-AN pumps is the high reliabil-

ity, the long maintenance intervals

and the service lives. These special

centrifugal pumps function in many

areas with a verified service life of

up to 32,000 operating hours for the

The design and technical particularities of the vertical self-regulating

centrifugal pump V-AN result in decisive advantages:

l In operating state they function self-ventilating and generally cavita-

tion-free (NPSHR < 0.01 m, because no pressure drop occurs at the

impeller wheel inlet). This ensures a high availability. There are no

NPSH problems whatsoever. This ensures operating at a high speed.

l The minimal suction head required means that neither an elaborate

pit nor a frame is necessary.

l The construction allows liquid pumping directly from the vacuum

without suction head. Discontinuous feed flows and condensates can

be tackled with ease.

l Pressure impacts are unlikely due to the continuous operation.

l In terms of operating safety they are ideal for gas containing media.

l They are constructed to be able to run dry and have a safe design.

l Even small capacities do not cause any regulating issues.

l Users worldwide have verified a very high operating reliability and long

service lives.

An overview of the advantages

Installation with standard horizontal pump

Condensate collecting vessel / feed

Condensate pumps in power plants

Level control

Flash tank Flash tank

Feed

LAL

LAHmax.

min.

Installation with centrifugal pump type V-AN

max.

min.

Sel

f-re

gula

ting

ar

ea

Gas compensation line

Condensate tank

mFig. 3 Right: cavitation-free, space-saving and uncomplicated pumping with the pump without suction capacity

Roten s.r.l. - Via Ortica, 6 - 20134 - Milano Tel. +39 02 76110157 r.a. - Fax +39 02 7385445 www.roten.it - info@roten.it

MILANO 1945

NOI SOSTENIAMO IL FAI - FONDO AMBIENTE ITALIANO

p Global 201410

EDURGERMANY

Dr. Jürgen Holdhof

Operating as a dynamic mixer

multiphase pumps provide

the gas enrichment of liquids. In a

lot of applications such as

l Waste water treatment by

means of dissolved air flotation

l Limy circulation water in the

paper industry

l Renewable energy

l Raw materials industry

l Ammonia Stripping

l Cooling Water Treatment

l Crude oil-water separation

these pumps enable huge and sus-

tainable process improvements.

Dissolved air flotation (DAF) is

a proven and well recognised proce-

dure for the treatment of water and

waste water and for the recovery

of recyclables as well and a typical

application for a multiphase pump

operating as a dynamic mixer. It

serves to simply separate substances

that are suspended or emulsified in

liquids. In doing so saturated water

is released to atmospheric pres-

sure with highly pressurised air and

guided into the waste water tank. The

micro bubbles that become free dur-

ing pressure release do settle on the

suspended materials and float them

to the liquid surface. From here they

are removed by skimming devices.

The special design of the mul-

tiphase pumps enables a direct gas

input into the suction pipe line. As

a result system components like

compressors, pressure tank, pumps,

control devices and valves are not

necessary compared to conventional

systems (l Fig. 1).

Typical fields of application

include the treatment of oil/water

emulsions, fat separation, phos-

phate precipitation and heavy metal

precipitations as well as secondary

clarifications in biological purifica-

tion plants. Multistage flotation

systems are also well-known for the

treatment of special waste. Many

plant manufacturers report that by

the use of multiphase pumps sav-

ings are not only made with regard

to investment volumes but also for

the continuous operating costs that

on average amount to between 30 %

and 40 % compared to conventional

systems depending on the plant type

(l Fig. 2).

Limy circulation water in the paper industry

In the paper industry calcare-

ous deposits from the circulation

water in pipes, cooling systems,

heat exchangers, etc. are avoided by

the use of lime traps. As a result the

freshwater demand is significantly

reduced and a sustainable improve-

ment of the process reliability is

achieved. The costs associated with

repair and maintenance of the sys-

tems are also significantly reduced.

Originally in a paper factory a

partial flow of approx. 288 m³/h was

saturated with compressed air in a

pressure reactor. The fed quantity of

compressed air was adjusted to ap-

prox. 400–500 l/min. For the flota-

tion aeration a standard pump with

75 kW motor power (QN 288 m³/h,

HN 6,5 bar, pump power input at QN

approx. 68 kW) as well as a 7,5 kW

compressor, a pressure reactor for

the preparation of the air-water

mixtures and a compressed air tank

were conventionally installed.

Under the same operating

conditions two multiphase pumps

each 18,5 kW with air input in front

of the pumps were installed. The

results indicated a perfect opera-

tion of the lime traps at a flow rate of

45 m³/h and a flow amount of 4 bar

incl. approx. 20 % air as well as a

pump power input of approx. 13 kW

per pump. A total of 75,5 kW (mo-

tor and compressor) was required in

the conventional system. In contrast

no compressor is required when the

multiphase pumps are used. The

pump power input of the two pumps

amounts to 26 kW only.

Consequently the total motor

power is reduced by 49 kW or re-

markable 65,6 %. At an energy price

of 0,10 € / kWh and an annual oper-

ating time of 8.000 hours (three shift

system), the annual energy savings

amount to approx. 39.600 €. The

energy-efficient reconstruction of

the plant was amortised after ap-

prox. 5 months.

Renewable energy

In the processing of regenera-

tive energy carriers such as biofuel,

wood, waste fractions with high heat

value, or animal meal to synthesic

gas the inert CO2 has to be washed

out. A compressor forwards the gas

into an absorption cell, where it

flows ascendingly through a sup-

port medium aggregate. This aggre-

gate is being sprayed from above

with water that is conveyed by an

Edur multiphase pump. During this

process the water is enriched with

the CO2 out of the synthesis gas.

Afterwards the water is led into a

desorption tank, in which most of

the CO2 will outgas. As this water still

is saturated for 100 %, gas bubbles

Multiphase Pumps for gassy liquids or gas enrichment

lFig. 1 System design

p Global 2014 11

EDURGERMANY

Result

Supreme process reliability,

energy efficiency, the simplification

of the plant concept and the associ-

ated reduction of plant components

that are susceptible to problems and

are maintenance-intensive result in

a wide acceptance of the innovative

multiphase concept. Both the im-

mense savings and the significantly

lower running costs compared to

the previous plant structure lead

to extremely short amortisation

times. Even the retrofitting of exist-

ing plants paid for itself after a short

period of time.

www.edur.com

crude oil. Flotation plants equipped

with multiphase pumps separate

the oil and water. The recovered oil

is further process and the water is

sent back to the drill holes. How-

ever, in contrast to industrial ap-

plications, the multiphase pumps

must be designed as super-duplex

pumps for resistance reasons. The

shaft sealing is executed according

to the so-called API plan (API 682 /

ISO 21049). Essentially, methane is

used in place of ambient air in order

to achieve separation.

above. Due to this sprinkling the

ammonia releases gaseous from

the waste water. It can be conveyed

by a gas pipe to the fertilizer pro-

duction process again.

Cooling Water Treatment

The innovative conception of

the Edur multiphase pumps did lead

to participation at seventh frame

programme of the EC for research

and technological development. Ma-

rine bio-fouling is a major problem

for materials in constant contact with

seawater. Accumulation of marine

organisms has impact on the proper

functioning of engines and further

appliances on board that need con-

stant und proper cooling, and on

the safety of the vessels. The project

comprises the development of a

system for avoiding bio-fouling, by

means of ozone improving the qual-

ity of the seawater for cooling the

ship’s engines and by this avoiding

considerable maintenance costs and

at the same time assuring a reliable

operation of the seagoing vessels.

Crude oil-water separation

Instead of hydro cyclones the

separation of the mixture can also be

performed using flotation technol-

ogy and multiphase pumps. There

is generally a significant amount of

oil-water mixture when conveying

occur during priming, that however

are soluted again by the multiphase

pump – the circuit starts again.

Raw materials industry

Most copper mining depends

on crude ore that is cracked, grinded

in rock crushers and subsequently

supplied towards the flotation. Fine

air bubbles transport the small min-

eral particles to the water surface

and keep them in the flotate. By

means of the water-air mixture and

adding of flotation additives at the

same time the copper ore is sepa-

rated from other ores. The ore con-

centrate subsequently is smelt in the

following process.

Ammonia Stripping

Downstream the fertilizer

production process a stripping

system is installed and serves for

reducing the ammonia nitrogen

content and also the chemical oxy-

gen demand (COD) in the process

waste water to the standard values.

Initially the waste water is fed into

the tank near ground level. From

there it is conducted into the mul-

tiphase pump where air is aspired

along with the water and brought

into solution under pressure. After

pressure release the generated

water-air mixture is delivered back

into the tank through nozzles from

lFig. 2 Municipal waste water treatment plant

Ohio, USA

Ponndorf Gerätetechnik GmbHLeipziger Straße 374 · D-34123 Kassel · info@ponndorf.de

Everything able to pass through the hose can be pumped. The solution for your requirements: 0561 - 511390

Hose Pumps

Extremely persistent· safe to run dry

· self-priming up

to 9,5 m H2O

… regardless of the media

· slurry · acids · colours

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e.d

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p Global 201412

FLOTRONICUNITED KINGDOM

the need for any secondary cham-

ber, with a control unit shutting the

pump down when activated.”

Flotronic designed the ‘H’ Se-

ries not only to meet 3-A’s stringent

criteria but also with the US market

particularly in mind. Meeting the

high standards demanded by 3-A is

a requirement of many US compa-

nies, especially those in the food

processing industry.

“While 3-A is not a statutory

requirement, it is a standard in-

creasingly required by the sanitary

industry and particularly in the Unit-

ed States,” says Flotronic’s Manag-

ing Director, Jane Waite. “Being au-

thorised to display the 3-A symbol

ensures credibility of the new ‘H’

series, at home and abroad.”

www.flotronicpumps.co.uk

surfaces polished to 32 μin Ra maxi-

mum and an electro-polished overall

finish also make cleaning effective.”

“We also knew that we needed

to find a cost-effective alternative to

our pneumatic rupture protection

system,” says Peter. “The re-

sult is an electrical unit con-

nected to sensors in the

pump’s air domes.

“Ease of cleaning and robust

rupture protection and associated

alarm systems are vital for 3-A ac-

creditation,” says Flotronic Chief

Engineer, Peter Wheal. “We were

confident that our ‘One-

Nut’ design would

completely satisfy

3-A cleaning

Ease of maintenance and electronic rupture protection secure

3-A accreditation Specialist air-operated double-dia-

phragm pump manufacturer, Flo-

tronic Pumps Limited, have secured

3-A accreditation for their brand new

‘H’ series pump. Among a number of

critical design features, the One-Nut

design, which allows rapid pump

disassembly and straightforward

cleaning in place, was crucial to the

success of the ‘H’ series’ 3-A ap-

plication. The ‘H’ series’ electronic

rather than pneumatic rupture pro-

tection system was also a deciding

factor.

3-A Sanitary Standards Inc is

an independent not-for-profit cor-

poration dedicated to advancing

hygienic equipment design

for the food, beverage, and

pharmaceutical industries.

It sets high standards for

cleanability of equip-

ment as well as for the

provenance of the

parts and raw

materials used

and the pump’s ability to shut-down

immediately to avoid contamination

in the event of a problem.

and maintenance demands. One-

Nut means that the pump can be

maintained in minutes with cleaning

made easier by a specially designed

support stand which allows full

rotation for draining. Wetted

p Global Online – www.delta-p-online.comNews, facts, developements about pumps + systems

The presence of any

leakage is immediately

detected avoiding

p Global 2014 13

FUJI ELECTRIC EUROPEGERMANY

Cooling water pumping systems

In big refrigeration equipment, a

water system is used to extract heat

from the condenser (in the refrigera-

tor cycle, the refrigerator gas is lique-

fied in the condenser) and send this

heat to a cooling tower.

The key parameter to control in

this cooling water system is the dif-

ferential of temperature between inlet

and outlet water. Using Fuji Electric

frequency inverters for controlling the

speed of the cooling water pump al-

lows the system integrator to keep the

differential of temperature constant

regardless of the system conditions.

Additionally, temperature sensors

can be easily used thanks to optional

equipment, thus it is not necessary to

use external controllers.

Application requirements

The basic solution for one

pump systems is based on Frenic-

HVAC inverter, using the inverter

built-in PID control. Temperature

sensors can be easily connected

by using OPC-PT optional card, and

the temperature differential can be

calculated in the inverter.

Basic control strategy is based

on an inverse PID control of the

temperature differential between

inlet and outlet water. Fast control

response for keeping the tempera-

ture differential constant regardless

of operating conditions is manda-

tory. Proper interface for connecting

to temperature sensors is highly

appreciated. Multi-pump control

might be a must in some applica-

tions.

For more complex applications,

where multi-pump schematics are

implemented, the recommended

solution is based on Frenic-Aqua in-

verter, using the inverter built-in PID

control (several multi-pump strate-

gies available). Temperature sensors

can be connected by using OPC-PT

option card.

Advantages of this solution

l Powerful PID control is built in

the inverter (1 main PID, 2 gains

set and 3 auxiliary PID). Multi-

pump complete controls and

compressor working time

balancing functions are avail-

able in Frenic Aqua inverter.

l OPC-PT optional card for con-

necting 2 temperature sensors:

2 channels are available for

JPt100, Pt100, Ni100, Pt1000

or Ni1000 sensor types

l Analog customizable logic

built-in: mathematical opera-

tions allow the inverter to

calculate the difference between

two analog signals. This can

simplify the system and it is

not necessary to use external

controllers.

l Mutual operation (multi-master

operation) is available in Frenic

Aqua inverters.

l Automatic energy savings func-

tion which allows reaching

higher energy savings’ rates at

low speeds.

l DC Reactor and EMC filter are

built in up to 90 kW (C2 support-

ed, 2nd environment supported);

EMC filter is built in from 110 kW

to 710 kW (C3 supported, 2nd

environment).

l Protective structure IP21 or IP55

can be selected with the model

up to 90 kW.

www.fujielectric-europe.com

p Global 201414

GATHERGERMANY

Pumping a solvent mixture at 450°C with 500 l/h

Sven Borghoff

For applications of superlatives the

Gather Industrie GmbH is getting

interested in always as like:

l Dosing 20 ml/h against 10 bar,

l Pumping liquids at low tem-

peratures down to –200 °C,

l producing lowshear and

sterilizable gear pumps,

l Circulating liquids that are

under a pressure of 325 bar at

300 °C or

l Spraying hot water through a

nozzle at 20 bar.

Basis for all of these solutions is

a magnetic drive process pump

– even for the extreme example

described below.

“We‘ve got a problem! Can

you still pump a solvent mixture

of 500 l/h at 450 °C? We are look-

ing for a hermetic pump, because

the mixture is a very critical one,

it’s under pressure and non-lubri-

m

Figure 1 Pumps in a rectification column

cating.” This specific inquiry was

the starting point for a solution

that fulfills three requirements at

once.

The facility plan (l Fig. 1)

shows a typical rectification column.

Gather pumps have already been

proven in many similar applications

very well as feed pump, circulation

pump and discharge pump. The task

described above is almost identical

– just to be solved at a higher tem-

perature.

Completed and combined several optimizations

Although the temperature of

450 °C is at the limit of what is pos-

sible for a magnetic coupling, but it

is just at the limit, not above! Non-

lubricating liquids can be handled

by every Gather pump anyway. But

as simple as the application looks

like, it isn’t at all: What about pos-

sible solids and what about cavita-

p Global 2014 15

GATHERGERMANY

into the internal circulation, where

they could cause great damages, so

easily. The turbine pump does not re-

quire any self-lubricating properties

from its impeller material, such as in

the gear pump requires from its gear.

The suitable material

At +450 °C the right materials

selection is not so easy. First and

foremost stainless steels and nickel

alloys have got sufficient strength

and chemical resistance. Because

the housing is in addition to the

temperature of +450 °C under a

sitive to any solids and withstands

larger particles. The reason is that in

this pump solids cannot get caught

pumps (l Fig. 2) ). For this applica-

tion the decision quickly came to the

turbine pump, as it is much less sen-

tion? These are the main reasons

why pumps fail, especially in com-

bination with lowviscosity liquids,

where even a little material wearout

reduces the capacity and lifetime

noticeably. So to solve this problem,

several optimizations had to be ex-

ecuted and brought together.

The pump type

Gather offers magnetic drive

gear pumps and centrifugal pumps

(side channel pumps or turbine

lFigure 2 Principle of

a turbine pump

p Global 201416

the technically feasibility under such

extreme conditions to the boundary

conditions. Nevertheless you have

to make compromises to achieve a

technical solution always.

www.gather-industrie.de

Extreme applications are not

technical challenges and particu-

larly consultation-intensive only.

The engineering is time-consuming

and requires many years of experi-

ence. There is a need to optimize

optimized conditions for the pump

so that it cannot run dry.

The specifics

Pumps used under such ex-

treme conditions need well-tried

components and a good basic con-

struction and there have to be cre-

ated the best working conditions. All

of that have been implemented in

this case, which have contributed to

an innovative process development.

This application shows impres-

sively how a standard product can

be developed by calculated modifi-

cations and variations to an appli-

cation-specific special solution for

extreme conditions. The basis for this

is a high quality, flexible constructed

standard that allows many variations

by its modular system. In this turbine

pump have been used developments,

which were originally designed for the

Gather gear pump only.

system pressure of 40 bar abs,

the strength of the materi-

als plays a very impor-

tant part. Due to the

required chemical

resistance simple

steels or other base

metals, which have

got significantly

higher strengths, had

been out of question.

As slide bearing the

decision came to the DLC bearing

system, which is a development of

Gather. The magnetic system of the

standard samarium cobalt is not

enough, because it can only be used

up to 350 °C. However, a special var-

iation of samarium cobalt magnets

can be used at higher temperatures.

The drive

So that the high temperature is

not transmitted to the drive, special

connecting parts have to be used in

this case. They need thin walls and

a very large surface in relation to its

volume or mass.

The successful operation of

this modified pump (l Fig. 3) re-

quires consideration of certain op-

erating conditions and optimized

system conditions. Thus, the inflow

to the pump was discussed in detail

with the plant operator to prevent

possible cavitation and to ensure

the highest possible life time of the

pump.

Now make big sized tube dia-

meters in addition to monitored

liquid level in the column sure

oFigure 3 The mini centrifugal pump

mFigure 4 Characteristic of the mini centrifugal pump

GATHERGERMANY

p Global 2014 17

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OSNA-Pumpen GmbHBrückenstrasse 3D-49090 OsnabrückPhone: +49 5411211-0Fax: +49 5411211-220Internet: www.osna.deeMail: info@osna.de

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Vogelsang & Benning Prozeßdatentechnik GmbH

Tel. + 49 (0) 2 32 75 47-0www.vogelsangbenning.de

Hansastraße 92D-44866 Bochum

We supply test systems for:

• Centrifugal pumps• Displacement pumps• Submersible pumps• Compressors• Booster stations

Test systems for the pump industry

Pumps for nearly any application – each one requiresa special testing system

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p Global 201418

Apa Nova Bucharest took over the responsi-

bility of running the Romanian capital’s water sup-

ply in 2000. Back then, the water network, includ-

ing pumping stations, was in very bad shape, no-

body had water meters in their houses, the water

supply was unstable and many pipes were leak-

On a daily basis, water company Apa Nova

Bucharest struggles with keeping pipes and

pumps up to speed. The latest initiative is to

implement a Demand Driven Distribution solution

from Grundfos, which can save both water and

energy.

Every time a person in Bucharest turns on the

tap, the water flows far. Around 2,500 kilometres

of pipes are hidden underground, transporting the

water from outside Bucharest into the city and its

more than two million inhabitants. Working on im-

proving pipes and pumps is privately-owned water

supply company Apa Nova Bucharest, part of the

Veolia Group.

ing. Since then, Apa Nova has improved the water

quality by changing approximately 20 kilometres

of pipes every year and optimising the pumps,

which means that the electric power consumption

has decreased by 70 per cent since 2000.b“We

have come a long way, but there is still room for

improvement, I must say. We are always striving

to do better, and I don’t think that I will ever be

completely satisfied”, he says.

Intelligent system

Arnaud Valleteau de Moulliac explains that

Apa Nova has already adjusted the more than

200 pumping stations connected to the systems.

GRUNDFOSDENMARK

Romanian utility company chases water leakages and energy savings

“We have quite an old water net-

work, so every day we are working

on optimising it so the inhabitants

of Bucharest get a stable water

supply. And we want to do it in a

way where we use less energy and

minimise loss of water”,

says Director Arnaud Valleteau de Moulliac.

GRUNDFOSDENMARK

too. “Our main driver is to use the most innovative

technology available, and the DDD solution is one

of them”, he explains.

www.grundfos.com

All pumps and installations were delivered by

Grundfos in the period from 2001 to 2009.

Searching for further savings, Apa Nova

has entered into a project with Grundfos in

which the Demand Driven Distribution (DDD)

solution is being implemented at a pumping

station, which delivers water to approximately

50,000 people.

The DDD solution consists of several paral-

lel connected pumps, running one or more at the

time according to the consumers’ needs. This will

not only save energy because of the intelligent

controller adapting output to the actual needs for

water throughout the day, it will also ensure that

the network is less stressed than normal, which

means water is not wasted due to leakages.

“We have a close cooperation with Grund-

fos, and we always invest time and money in our

network. We see this as a good opportunity to

see how much more we can lower our energy

consumption and water leakages”, he says, ex-

plaining that a DDD solution will be the icing on

the cake.

Spread out the solution

At the Titan pumping station in eastern

Bucharest, the pumps are driving water through

the 24 kilometres of pipes in the surrounding

area. But the DDD solution can make the pumps

run even more efficiently, according to Sales

Manager for Water Utility in Grundfos Romania

Leonard Stroe.

“Right now, we are measuring how much en-

ergy is being used when we run the pumps more

intelligently using a special controller, and we can

see that it is possible to save up to 15 per cent in

this area”, he says, “highlighting that the number

could be higher at other pumping stations”.

In other cities, where the water network

runs with a constant pressure, the potential sav-

ings can be up to 50 per cent.

THE ENDURERSFOR EXTREME DUTY POWER TRANSMISSION:OUR ZERO MAINTENANCE DISC PACK COUPLINGS.

THE COUPLING.RW-COUPLINGS.COM

Arnaud Valleteau de Moulliac explains that

the area being tested is representative for a part

of the high-pressure network, and he expects that

the solution can be used at other pumping stations,

p via Xing + TwitterNews directly from

the publisher

pPump Innovations Guide

Mobile Editionfor Smartphones and Tablet-PCs

www.deltap.me

MASTHEADp Global

p Global is the worldwide partner magazine of the Unique German Pump Magazine p.It concentrates exclusively on pump technology, techniques for transporting and dosing of liquids, fluids and gas as well as their applications

Publisher Rüdiger Nagel

Editorial department Rüdiger Nagel Phone + 49 71 27 / 5 66 09 ruediger.nagel@pumps-directory.com

Advertising department Birgit Epple, Sandra Kühnle Phone + 49 71 27 / 5 66 09 birgit.epple@pumps-directory.com sandra.kuehnle@pumps-directory.com

Circulation department Vertriebsunion Meynen P.O.B. 1153, D-Eltville

Typesetting Medien.Gestaltung Schweizer Echterdinger Straße 57 D-70794 Filderstadt

Printing W. Kohlhammer Druckerei GmbH + Co. Augsburger Straße 722 D-70329 Stuttgart

Issues 5 issues p and 1 issue p Global

Circulation 6.000 copies

Company ingenieur verlag nagel P.O.B. 11 64 D-72627 Aichtal Germany Telefon + 49 71 27 / 5 66 09 Fax + 49 71 27 / 5 66 49 E-Mail ruediger.nagel@pumps-directory.com

©B

ICO

M_1

2710

.02

0.09

.201

4

It has never been easier to improve your processes than today! Our new TURBOVAC (T) 350 i and 450 i with integrated electronic drive will allow you to optimize pump-down times and consistently hit your target regarding pressures and gas flows. Designed to offer the best performance:size ratio available in the ISO 100/160 size range, they feature a rotor and drag stage design to achieve maximum performance and unparalleled speed, especially for light gases. This new product line is supplemented by the most flexible multi-inlet turbomolecular pumps TURBOVAC 350 - 400 i MI. Intended for therequirements of analytical instruments, multi-inlet pumps are prepared for individual design customization to provide an optimum process adaptation.

Oerlikon Leybold Vacuum GmbHBonner Straße 498D-50968 KölnT +49 (0)221 347-0F +49 (0)221 347-1250info.vacuum@oerlikon.comwww.oerlikon.com/leyboldvacuum

TURBOVAC iTurbomolecular pumps

A giant leap in vacuum performance!

The TURBOVAC i series 350 i, 450 i and 350-400 i MI at a glance

p Global 201422

Pumps represent without a doubt the cen-

terpiece of every swimming pool. Optimum

filtration and water circulation depend to a large

extent on having the right and in particular ap-

propriate pump installed. And if a swimming

pool pump additionally fulfills all technological

performance parameters in terms of efficiency

and energy consumption, then that should be

every reason for you to enjoy your own pool.

The new TriStar VS filter pump from Hayward

represents an efficient, ecologically convincing

solution. The swimming pool pump allows you

to select between three preprogrammed speeds

that can be adjusted in steps of 10 rpm and was

especially developed for use in private pools. The

pump is well suited both for installation in new

modern swimming pools as well as for modern-

HANNINGGERMANY

mFig. 1 The hamotic varicon compact synchronous drive delivers high efficiency and offers low life cycle costs

qFig. 2 The TriStar VS pool

pump with variable speeds

State-of-the-art pump drive ensures swimming fun

State-of-the-art pump drive ensures swimming fun

p Global 2014 23

izing existing systems. Operators of the inno-

vative TriStar VS benefit from the wide variety

of advantages. The pump is easy to install,

is intuitively operatable thanks to its control

module and delivers reliable operation. When

it comes to running, the TriStar VS is extremely

silent and highly efficient. Moreover, a large

prefilter basket with viewing window reduces

the frequency at which the filter needs to be

cleaned.

Energy-saving pump drive

The hamotic varicon compact synchro-

nous drive forms the heart of the TriStar VS

pool pump. The drive which features perma-

nent magnets and electronic AC circuitry is

equipped with sealed-for-life ball bearings, a

stainless steel shaft and a customized pump

flange. The hamotic varicon is small, rugged

and powerful. This compact powerpack with

embedded NdFeB magnets is reliable and

precise with high concentricity. The motor in

the 71/90 size delivers an output of 0.55 to

1.1 kW and exceeds the efficiency require-

ments as per IE3, which will start to apply to

drives in 2017. As a result, this drive fulfills

with its integrated power control electronics

and individually upgradeable functionality all

expectations regarding an optimally matched

pool system.

All pumps of the variable speed TriStar

VS product line are operated at optimum

efficiency and precisely deliver the capac-

ity required by the respective application

– based on the individual requirements and

size of the swimming pool. Coupled with ex-

ceptional hydraulic capacities, the high en-

ergy efficiency results in a potential savings

of up to 70 % in terms of power consump-

tion. A precise concentric run-out over the

entire speed range also minimizes the material

fatigue of the components. That affects the ser-

vice life of the installed pump system and thus

the maintenance and repair costs of the entire

system. Even ripple moments are prevented

thanks to a suitable design. Another bonus is

the minimal noise emission level of the low-

vibration drive due to its high running smoothness.

High-quality electronic module

The high-quality electronic module is inte-

grated in the motor’s end shield, where the circuit

boards have a water-repellent nanocoating to pre-

vent damage due to the formation of condensation.

A tried-and-tested power module, a digital signal

HANNINGGERMANY

Standard features with:

detachable operating unit

multi-layer safety diaphragm

internal overload cut-off

state-of-the-art control technology and more

than 10% energy savings potential

www.prominent.com/en/sigmaTelefon: +49 6221 842-0

For those who want more –the best Sigma ever!

METERING MEASUREMENT & CONTROL TREATMENT DISINFECTION IMPLEMENTATION

The new Sigma motor-driven metering pump.Greater operating convenience, better safety, greater cost effi ciency!

p Global 201424

er enables the configuration of up to five

different speed settings per day. As an

alternative, the skimming function can

also be configured to automatically skim

the pool’s surface every three hours.

The three configurable speeds (V1,

V2, V3) allows adaption of the pump to

every pool size by adjusting the speed

from 600 to 3,000 rpm in intervals of

10 rpm. The filter speed V1 is recom-

mended for cold water and when the

swimming season is over. When the filter

speed is set to V2 with 24-hour circula-

tion, the TriStar VS works constantly and is

extremely silent at low speed. Chemical residues,

salts, dirt and sand are filtered while the pH level

is regulated at all times. The powerful V3 setting

is used for counter-washing processes or specific

applications, for instance, a pool owner has ad-

ditional equipment such as

a chlorinator or heat pump

which are used to heat up the

water’s temperature.

Hayward provides cus-

tomers with a simulation tool

that calculates the expected

amount of energy saved af-

ter specific pool details like

shape, size, type, etc. have

been entered. The variable

speed TriStar VS from Hay-

ward pays for itself within

three seasons.

www.hanning-hew.de

ture or power consumption. As a result, pool own-

ers can see the pump’s status any time. Besides

having a simple run/stop switch, it also allows the

user to set up special programs. An integrated tim-

processor with state-of-the-art con-

trol algorithms, which allows the

connection to household power

grids, and comprehensive protec-

tive circuits monitor the drive’s

operational reliability. The mains

input is equipped with a Power Fac-

tor Correction (PFC) that fulfills the

harmonic current emissions accord-

ing to standard IEC/EN 61000-3-2.

The module also comes with an

EMI filter for residential environ-

ments and a thermal overload

protection.

Intuitive display and real-time information

The integrated, user-friendly control display

features rugged buttons. It provides real-time

information on energy consumption and other

essential parameters like speed, torque, tempera-

mFig. 4 Characteristic curve of the three speeds V1 to V3 based on output in m³/h

kFig. 3 The control display

of the pool pump is equipped with touch-sensitive buttons

HANNINGGERMANY

p Global 2014 25

HERBORNERGERMANY

Sewage and vacuum pumps combined in a drainage system

The Unipump-V comes stand-

ard equipped with a highly-efficient

motor with efficiency class IE2. The

reduced energy consumption in

combination with the higher operat-

ing safety offered by the Unipump-V

makes economically-viable conti-

nuous operation possible.

www.herborner-pumpen.de

The centralised positioning

of the motor is very space-saving,

which in turn means that the pump

can be installed in the narrowest or

tightest of areas. The easy integra-

tion into existing systems is guar-

anteed as a result and the system

operates with only limited noise

emissions.

The pump is powered by a ro-

bustly constructed surface-cooled,

three-phase squirrel cage motor with

reinforced drive-shaft and bearings

that is designed to stand up to the very

toughest operating conditions associ-

ated with sewage transport. The mo-

tor, which is located underneath the

vacuum pump, powers both pumps

and is the heart of the entire unit.

This pump combination is also

offered either as a sewage pump with

a dry-running slide-vane rotary vacu-

um pump or a claw pump as a single

pump, or in combination with a collect-

ing tank for the purpose of separating

the air-sewage mixture. The Herborner

Pump Factory also offers a control sys-

tem with which to operate the plant

as well as a complete system. The

compact plants can be provided with

either one or two Unipump-V pumps.

The newly developed Unipump-V from

Herborner Pumpenfabrik is excellently

suited for use in small and medium-

sized vacuum drainage systems. The

compact unit, in which the sewage

and vacuum pumps are combined with

one another, can be used to generate

the vacuum as well as to convey the

sewage in the piping system. The Un-

ipump-V is designed and constructed

so as to provide high operational secu-

rity and failure-free functioning for on-

shore facilities in constant operation.

The open, radial through-flow

single-channel impeller with its wide

and non-constricted opening en-

sures that the Unipump-V provides

unrestricted sewage transport. The

integrated, self-acting fibre-cutting

system ensures reliable pumping

operation even in the event of sig-

nificantly contaminated media.

www.ktr.com

Easy assembly and safe power transmission thanks to the split hub design and our advanced T-PUR® spiders.

Just two of many reasons why ROTEX® S-H with split hubs is ideal for use in pump drives.

One less problemCCD Süd

225

26 p Global 2014

HNP MIKROSYSTEMEGERMANY

For many machine and system

manufacturers, pumping, convey-

ing and metering is their daily busi-

ness. However, when dealing with

minimal quantities of low or high-

ly-viscous fluids, the task quickly

turns into a challenge. Additional

demands such as a high differen-

tial pressure, aggressive liquids

and maximum precision sometimes

make the task appear unsolvable.

However, many of these extremely

demanding metering jobs can be

mastered – with the aid of micro

annular gear pumps.

Five series of mzr®-pumps

permit a multitude of applications.

With differing equipment, meter-

ing volumes from 0.25 μl, volume

flows from 1 μl/h to 1.1 l/min and

pressures from 0 to max. 150 bar

can be realized. The range of

media viscosity extends from 0.3 to

1,000,000 mPas. The pumps are

suitable for lubricating and non-lu-

bricating media. Operation in areas

protected against explosions is also

possible.

One application field of many

is the coating technology. Here mzr-

pumps supply spray systems and slot

dies with liquids for the application

of very thin layers. The low pulsation

flow rate guarantees that minimal vol-

ume flows of 0.1 to 500 ml/min can

be constantly applied across many

square meters of surface. The proce-

dure is used for the coating of stents

with medication, glasses lens and

solar cells with functional layers and

wavers or DVDs with layers of paint,

and also in the production of organic

electronics and battery systems.

Furthermore, the characteris-

tics of the mzr-pump permits its in-

tegration into devices for DNA analy-

sis, blood analysis, but also in open

pipetting systems in which the user

can program their requirements ac-

cording to liquid handling tasks. Due

to their compact construction, they

are predestined for the realization

of projects for device miniaturiza-

tion, as on the one hand the pump

principle permits low pulsation me-

tering of shear-sensitive liquids, and

on the other hand it is possible to

take up and deposit small quantities

of liquid using the mzr-pump (aspi-

ration and dispensing) or to convey

high volume flows continuously, for

example for a cleaning process. All

three functions can be conducted by

the same pump, and thus simplify

the liquid organization in analysis

can be metered to a precision of 1 %.

Further application fields are

the metering and dispensing of hot

melt adhesives for efficient and

long-term stability joining process-

es, the highly-dynamic and precise

minimum quantity metering and dis-

pensing of greases, and the highly-

accurate filling of minimal quantities

of oil, grease, alcohol and many oth-

er liquids. Pump materials which are

resistant to wear and corrosion per-

mit numerous applications in chemi-

cal and pharmaceutical production.

Function of the smallest annular gear pump in the world

The micro annular gear pump

(mzr-pump) belongs to the group of

rotary positive displacement pumps

on which the displacer consists

of two components: an externally

toothed inner rotor and an internally

toothed external rotor, whereby the

external rotor has one tooth more.

A precisely controlled electric motor

drives the inner rotor, which in turn

takes the rotatable-mounted exter-

nal rotor with it. During rotation, the

eccentrically mounted rotors form a

system of several sealed pumping

chambers which increase on the

induction side and simultaneously

decrease on the delivery side. In

this way, an even and low pulsation

flow rate is generated between the

kidney-shaped inlet and outlet,

which simultaneously connects

several pumping chambers.

www.hnp-mikrosysteme.de

Smallest annular gear pump

1 2 3 4

Internal Rotor

Outlet

Suction Side Pressure Side

External Rotor

Inlet

mFig. 1 Operation principle of micro annular gear pumps

pFig. 2 mzr-pumps permit a multitude of applications

Flotronic puts the ‘H’ in hygiene.

The new 3-A accredited hygienic ‘H’ series pump.

With our unique ‘ONE-NUT’ design, 316L Stainless Steel polished to ° rotating

3-A accredited.

With the focus on food hygiene greater than ever before, you need equipment that doesn’t compromise your clean and sterile processing environments.

Equipment you can really trust.

The new 3-A accreditated ‘H’ series of 10” pumps – from Flotronic.

For more information call Flotronic Pumps Limited now on +44 (0)1444 881871 or email Flotronic at: sales@flotronicpumps.co.uk

www.flotronicpumps.co.uk

engineering for a better world

GEA Tuchenhagen offers a complete range of normal-priming and self-priming centrifugal pumps, perfectly tuned to the task at hand.

Reduced energy consumption Gentle product handling Hygienic design Capacity range of 1 m³/h up to 210 m³/h Optimal SIP/CIP characteristics EHEDG approved and certifi ed

Whatever your process, GEA Tuchenhagen has a clever solution for you.

GEA Tuchenhagen GmbHAm Industriepark 2–1021514 Büchen, GermanyPhone +49 4155 49-0

sales.geatuchenhagen@gea.com www.gea.com

Efficient conveying of liquids

p Global 2014 27

p Global 201428

HOMAGERMANY

High efficiency due to optimized motors and hydraulics

Energy efficiency in wastewater dis-

posal is now also of big importance,

as it largely determines the econo-

my. To be able to further increase the

efficiency of the submersible pumps

used here, Homa Pumpenfabrik Ger-

many, which is specialized in this

technology, has now redesigned the

motor and hydraulics of their units:

Not only the efficiency of the mo-

tors has been improved but thanks

to a permanent motor cooling, all

types of the new EffTec Series can

be operated in an immersed or dried

state. This allows a variety of moni-

toring capabilities, which can be

implemented right from the small-

est motor size. The hydraulics was

mechanically optimized, which they

are now distinguished not only by

their high efficiency but also through

a particularly running smoothness,

which additionally increases the

service life of the already overall very

robust design.

“A submersible pump with

all its components—the motor and

hydraulics—must work efficiently

in order to achieve the greatest

overall efficiency and the lowest en-

ergy consumption,” explains Martin

Senkowski, Head of Design and De-

velopment at Homa. Therefore the

company, which has its core compe-

tence, is in the field, created initially

a new concept for the engines, which

can now be set up either wet or dry.

This is made possible by the Per-

maCool system, a new, permanent

motor cooling. In addition, the new

motor generation allows respond-

ing more specifically to special re-

quests from customers: Among other

things, during the designing of the

units, great importance was placed

on the fact that all standard moni-

toring devices are feasible even for

small engines.

At the same time, the new de-

sign ensures that the cooling jacket

cannot clog with solids matters, re-

sulting in a high operational reliabil-

ity is achieved. This is further sup-

ported by the mechanically robust

construction and the low winding

temperature, which leads to lower

thermal stresses and hence to a

longer service life. The efficiency of

the engines could be improved sig-

nificantly; the models of the EffTec

Series are therefore in compliance

with the Premium Efficiency IE 3

class.

To achieve a high overall ef-

ficiency, the hydraulics has been

changed in conjunction with the mo-

tor: In particular, the essential com-

ponents of any centrifugal pump,

the impeller and the pump housing

have been completely redesigned.

“The nature of the wastewater has

changed significantly in recent

years; it always contains more solids

and less water. Therefore, a pump

is needed that works reliably under

such conditions,” explains Senkows-

ki. Therefore, the new series uses

only closed single channel impellers

with large ball passages, i.e. a large

free passage for solids. To achieve

the technically difficult optimization

of these components, Homa fell back

on its decades of experience and

combined them with modern flow

simulation software. In this way, it

was able to significantly improve the

efficiency of the single channel im-

pellers, while providing a low risk of

clogging. In addition, the hydraulics

were mechanically revised, allowing

the EffTec Series to have a very high

running smoothness, which mini-

mizes the stress on all components.

www.homapumpen.de

KLAUS UNIONGERMANY

p Global 2014 29

Twin Screw Pump

Energy EfficientDouble VoluteEnergy EfficientDouble Volute

Klaus Union is well known as

one of the world’s leading

manufacturers of magnet driven

and conventionally sealed centri-

fugal pumps. Since 2013, Klaus

Union’s product portfolio is com-

plemented with a range Double

Volute Twin Screw Pumps. These

pumps of the Series DSP are ro-

tary positive displacement pumps

which have a wide field of applica-

tions. They are used in the Oil and

Gas Industry, the Chemical and

Petrochemical Industry, Tank Stor-

age Facilities, Shipbuilding and

Power Generation.

The pumps are self priming

up to 8,5 mwc and transport high

or low viscous products,

corrosive or neutral, clean or con-

taminated as well as lubricating and

non-lubricating products gentle and

with low pulsation. Today, a major

objective of the end users worldwide

is energy efficient rotating machinery

which helps to reduce the consump-

tion and costs of electrical energy or

fossile fuels.

Screw Design with Special Flanks

This range of Double Volute

Twin Screw Pumps is equipped with

a new generation of rotating ele-

ments. The screws from single piece

bar stock have screw packages with

a special flank geometry. This spe-

cial design offers a considerable

reduction of the absorbed power

compared to conventional screw

executions. Optimized inlet and

outlet sections of the screw pack-

ages guarantee a smooth and al-

most pulsation free flow. The screws

manufactured from hardened carbon

steel are standard. Various grades of

stainless steel can be offered when

corrosive products are handled. To

minimize wear the screw packages

can be coated with Tungsten Car-

bide if the pumped product contains

abrasive solids.

Flow Rates up to 5,000 m³/h

These pumps are available in

three pressure ranges:

l low pressure range with up to

16 bar,

l medium pressure range up to

50 bar and

l high pressure range up to

100 bar.

Flow rates between 20 m³/h

and 5,000 m³/h at viscosities up

to 100,000 mm²/s can be handled

with the various pump sizes. De-

pending on the size and application

the pumps operate at synchronous

speeds of up to 3,600 min–1. Vari-

able Frequency Drives (VFD) are used

for a wide operating envelope and

changing duty points.

Pump Design

As a result of the double volute

design the new Twin Screw Pumps

Twin Screw Pump

q

Fig. 1

Double Volute Twin Screw

Pump Series DSP

p Global 201430

KLAUS UNIONGERMANY

fields. Most of these fields produce

high gas flows and small amounts

of hydrocarbon liquid and water.

Usually, the well pressures are very

low. This does not allow the use of

conventional separation systems

and and even artificial lift by means

of gas lift or downhole pumps. Du-

ring the past decades Multiphase

Pumping Systems have replaced

many conventional separation sys-

tems on the oil fields world wide.

They operate at very low positive

suction pressures and transfer the

well flow to central treatment fa-

cilities through just one pipeline.

The systems are compact with low

impact on the environment and

maintenance friendly. Multiphase

Pumping Systems also contribute

to reduced release of Greenhouse

gases at the wellsites by venting

and flaring.

The flow rates and pressure

ranges of the DSP Multiphase Pump-

eration. They are used as pipeline

pumps, pipeline start-up pumps,

slop pumps, loading and unload-

ing pumps, circulation and transfer

pumps for raw and finished products

and all kinds of feed stock.

DSP Multiphase Pumping Systems

Beside pumps for liquids, Mul-

tiphase Pumping Systems based on

the technology of the Double Volute

Twin Screw Pumps of the Series DSP

are available. These pumps can han-

dle mixtures of gas and liquids with

a gas content (GVF) in excess of 97 %.

During the past decades the

world experienced an increased

demand for crude oil and petro-

leum gas. In addition to the proven

production technologies, many

oil companies considered the re-

vival of abandoned oilfields or the

further development of marginal

suction flanges to guarantee a low

inlet velocity and hence, low NPSHR

values. The suction flanges can be

either on the right or left side view-

ing the drive shaft end. Heating pro-

visions can be supplied for all pump

casings. The casing covers are made

from carbon or stainless steel match-

ing the material grade of the casted

casing.

The pumps of the Series DSP

are designed in accordance with the

requirements of API 676, 3rd Edition

and additionally, all relevant nation-

al and international standards have

been considered.

Applications

Double Volute Twin Screw

Pumps have wide fields of applica-

tions in the Oil and Gas Industry,

the Chemical and Petrochemical

Industry, Tank Storage Facilities,

Shipbuilding and Power Gen-

Series DSP are hydraulically bal-

anced without thrust loads. The

torque is transmitted from the drive

shaft to the idler shaft by easy-to-

adjust herringbone gears which are

located at the non-driving end of the

pumps. The screws are carried in

heavy duty oil lubricated roller bear-

ings designed for a L10 life of more

than 25,000 h. Amply sized finned

bearing and gear covers guarantee

sufficient heat dissipation and re-

duce the necessity of external lubri-

cation systems with coolers.

The pump shafts are sealed by

single or double acting mechanical

seals which are exposed to suction

pressure only. Seal materials and

design are always adapted to the

particular operating conditions. Car-

tridge seals following API 682 can

be installed and delivered with cor-

responding seal flushing systems.

All DSP pumps are equipped

with replaceable casing inserts.

Pump casings and casing inserts

are made from cast carbon steel as

a standard. Optionally, a large va-

riety of Austenitic or Duplex Stain-

less Steel Grades are available. All

DSP pumps have particularly large

o

Fig. 2

Screw Assembly of a Double Volute

Twin Screw Pump Series DSP

p Global 2014 31

ing Systems correspond with those

of the industrial pumps. For applica-

tions where gas slugs are expected

during operation Liquid Control

Systems can be installed. The sys-

tem is integrated on the pump skid

and separates during operation con-

stantly liquid from the multiphase

flow which is collected in a vessel.

Approximately 3.0 % of the the total

pump flow rate is than re-injected

into the suction area of the pump in

order to create a liquid seal between

screw tips and liner. This liquid seal

is required to maintain the gas com-

pression even in absence of any liq-

uid from the well.

DSP Multiphase Pump Systems

are driven by electric motors or com-

l

Fig. 3

Delivery of a DSP Double

Volute Twin Screw Pump

bustion engines. Extensive instru-

mentation for monitoring pressures,

temperatures and vibrations is in-

stalled on the skid. Further compo-

nents as on-skid piping with motor

operated valves, filters, variable fre-

quency drives, PLC’s, transformers

and even container for the pumps

and the control equipment complete

the packages.

www.klaus-union.com

KLAUS UNIONGERMANY

AN ABUNDANCE OF EMPTINESS

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A trend-setting modern creation is needed in order to completely empty a tanker. The self-regulating V-AN centrifugal pump manages to perfectly master this art. Whether transporting boiling media up to the surface from below ground or by means of suction from above – this pump will immediately captivate the observer.

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32 p Global 2014

pump persuades with con T he MX progressing cavity pump has been on

the market for ten years – a time in which it

has conquered a wide variety of areas of applica-

tion. Its many strengths are responsible for this,

such as the high pressure that can be generated

despite its small dimensions, and its hygienic

construction.

The essential feature of the MX progressing

cavity pump is its use of the EvenWall® technol-

ogy, which differs considerably from conventional

designs. With EvenWall the stator sheathing is

adapted to the contour of the rotor, and – in the

standard model – it has an elastomer coating with

an even wall thickness. This provides numerous

benefits

l much greater pressure stability,

l less backflow,

l longer durability,

l better efficiency,

l less shearing of the product,

l and better suction behavior.

In addition, with a closed chamber, the MX

pump provides pressure of at least 10 bar. Thanks

to its multi-stage construction, the MX progressing

cavity pump achieves pressures of up to 80 bar.

Furthermore, every MX pump, regardless of

its size and design, is made with a bearing block.

Thanks to the use of the bearing block, the pump

can be supplied without a drive unit. The pump

user receives the advantages of a stand-by pump

that can be used immediately for which no time-

consuming mounting or shaft sealing unit is re-

quired. Advantageous is that the axial forces are

absorbed by the bearing block, so that they do not

have to be taken into account for the design of the

drive motor. This way, smaller drive dimensions

can be used.

A typical characteristic of the MX progressing

cavity pump is its hygienic suitability. CIP and SIP

cleaning are standard. This means that the pump

is constructed with little dead space and so that it

can be cleaned where it is used without dismount-

ing. The material selection, constructive arrange-

ment of the O-rings and surface properties fulfill

the guidelines according to EHEDG, QHD, GMP,

and 3A.

Numerous standard and special solutions

These progressing cavity pumps are – from

the small MX10 to the XXL version MX100 – avail-

able in many standard models. There are suction,

hopper, submerged, plasticizing, and double plate

versions. Thanks to their modular construction,

Progressing cavity KNOLL

GERMANY Progressing cavity

pump persuades with con m

The largest Knoll MX 100 progressing cavity pump in a suction version: like all models, it distinguishes itself through its compact construction, the high pressure it can generate, and its hygienic construction.

kFor use at IsernHäger, the MX 30R

progressing cavity pump was adapted individually to the needs of mixing dough.

(Illustration: IsernHäger)

20T progressing cavity pump used at FreiLacke is

joint-free. A titanium member that balances out

the eccentric motion of the rotor and eliminates

the need for cardan joints ensures this. Thus only

stainless steel and the sealing material PTFE come

into contact with products and cleansers within

the pump, so that neither the paints and lacquers

containing solvents nor aggressive cleansers can

do any harm.

The submergible version of the MX50 in marine use

Knoll has even developed a special pump so-

lution for use on tanker ships. MariFlex, one of the

world’s largest system suppliers in the shipping

sector, has integrated the MX progressing cavity

pump into its solutions due to its high conveying

power with a small and light construction. For this,

an especially short submergible MX 50T 80/10

was adapted so that it can be driven by a hydraulic

motor. The drive also handles the storage of the

pump, which saves weight. For the long transport

distances in the harbor or from ship to ship, the

high pressure of the MX50T 80/10 progressing

cavity pump is a big time-saving advantage: when

pumping molasses and oil, it can achieve a flow

rate of 50 t/h at a speed of approximately 450 rpm.

blog.mx-pumpen.de

www.knoll-mb.de

they are suited both for use in the hygiene area

as well as for the chemical and other industries.

In the food sector, Knoll has supplied the

MX pump for a system for pasteurizing sauces.

These high-viscosity media have to be transported

through long pipelines. The MX progressing cav-

ity pump convey its transport medium with little

pulsation. The evenly-generated rate of delivery is

of special advantage if there should be dosing im-

mediately afterward.

IsernHäger, a pioneer in machine-controlled

pre- and sourdoughs, decided to use an individu-

ally configureted progressing cavity pump. A hop-

per version of the type MX 30R was fitted with a

suction housing with a relatively large diameter.

The cleaning connections present for the CIP pro-

cess are equipped wih nozzles so that they can

also be used for the supply of fresh water. Further-

more, the pump was adapted with a large screw

conveyor, which offers an overfeeding of the pump

set, thus allowing a mixing of the dough ingredi-

ents within the housing. The welded and ground

screw conveyor is also polished and tumble pol-

ished to remove even the finest irregularities.

However, Knoll can offer MX solutions for

even more extreme conditions. Thus the manu-

facturer developed an elastomer and joint-free

variant of its MX progressing cavity pump for

FreiLacke. Here, resistant PTFE is used for the sta-

tor and the secondary seals. In addition, the MX

structive details structive detailsm

Lightweight MX50T-80/10 progressing cavity pumps with hydraulic drive unload ship tanks with a high delivery rate and they make high pressure available. (Illustration: MariFlex)

KNOLLGERMANY

Smartly connectT he perfect interplay of pump,

motor and drive controller is

well-known to be the key to pro-

nounced energy-saving potential.

Especially with small and medium

pump sizes with drive inputs of up

to 22 kW, a drive controller built

directly onto the motor has proven

to be particularly economically ef-

ficient. An increasing number of

pump manufacturers are making

use of the Inveor drive control-

ler platform to this purpose. It is

particularly flexible and can be

adapted to various pumps and

motors. This drive controller plat-

form is developed and produced by

Kostal. Dipl.-Oec. Markus Vetter,

head of marketing and communica-

tion at Kostal Industrial Electronics,

introduced us to the company.

The Kostal Group is an inde-

pendent family-owned company

founded by Leopold Kostal in Lüden-

scheid in 1912. He started there with

the production of installation materi-

als for industrial and private applica-

tions. Over the years, both his son

Kurt and his grandson Helmut Kostal

contributed their entrepreneurial

spirit to the family-owned business.

Since January 2011, the company

has been in the hands of the fourth

generation under the leadership of

Andreas Kostal.

In 1927, the company ventured

into the sector of automotive electri-

cal systems with a self-developed

turn indicator for automobiles. In

the following years a clear focus on

the development and production of

electromechanical components for

the automotive industry emerged.

In many cases, products originated

from the numerous developments

for the automotive industry that

were also used in other industrial

sectors. These product diversifica-

tions were bundled in 1995 in Ko-

stal Industrial Electronics, with the

goal of being able to offer these new

competencies and products more

intensively to the various markets

and to advance developments more

consistently. This is why Helmut Ko-

stal divided the group into four inde-

pendent business divisions: Auto-

motive Electrical Systems, Industrial

Electronics, Connectors and Soma

Test Technology. These areas are

equipped with their own resources

and capital in order to ensure the

independence of the divisions from

one another.

In 2004, Kostal Industrial Elec-

tronics was transformed into an in-

dependent private limited company

(GmbH), which moved to the Hagen

location in 2005. The activities of

Kostal Industrial Electronics today

focus primarily on two core areas –

l photovoltaics and

l drive technology.

The Kostal Group with its nearly

15,000 employees at 39 locations

achieves an annual turnover of

around 2 billion euros. The company

generally invests more than 7 % of

its turnover in research and develop-

ment.

for many possible combinations, allowing

-

mented and giving the customer the right

solution for a given set of requirements.

The special feature of our Inveor platform

most varied applications at a uniform

technological and thus highly economical

very high degree of individualisation based

on a modularised components standard.

especially attractive for the pump industry,”

Dipl.-Oec. Markus Vetter, head of marketing and communication at Kostal Industrial Electronics

Smartly connect

KOSTALGERMANY

p Global 201434

p Global 2014 35

KOSTALGERMANY

pump and motor

The cradle of the Inveor platform

“The drive technology at Kostal

Industrial Electronics is clearly

oriented to drive controllers and

frequency inverters,” according to

Vetter. “In this product sector we

can refer to extensive experience,

because here we have been carry-

ing out such developments for OEMs

and delivering these products for

many years. Even today, many of

our products are being used by well-

known customers. From these cus-

tomer relationships we draw upon

a large wealth of experience with

regard to the requirements made of

frequency converters. How should

a frequency inverter look? Under

which of the most varied ambient

conditions should it run? What sizes

and what performance categories

should it have? All of this led to us,

form is thus that it can be configured

for the most varied applications at a

uniform technological and thus high-

ly economical production level. With

Inveor we offer a very high degree of

individualisation based on a modu-

larised components standard. We

are certain that we offer our Inveor

drive controller with a cost-benefit

ratio that is especially attractive for

the pump industry,” according to

Vetter. “Inveor also embodies the

idea of efficiency down to the last

detail. An adaptation concept allows

the drive controller to be used with

all common types of motor, includ-

ing synchronous, asynchronous and

EC motors. In addition, Inveor can be

operated and programmed intuitive-

ly, meaning that every user will also

find the appropriate solution here.”

“Because we demand of our-

selves that we cover the entire value-

added chain and reflect our high

level of technological competence

and our brand promise, we place our

trust in a very high vertical range of

manufacture. Of course we can’t do

everything ourselves, but we strive

to offer that which we do to our cus-

tomers in the best possible qual-

ity. In our own plants you will find

everything, from fully automatic PCB

loading through wave soldering sys-

tems to final assembly and 100 %

inspection of the devices.”

Pump drive controller now from 0.25 kW

At the end of last year, at the

SPS IPC Drives trade fair in Nurem-

berg, Kostal introduced the Inveor

to round off the Inveor platform.

pump and motor

kThe modular Inveor

with an orientation toward this per-

formance portfolio, being able to

develop a completely new frequency

inverter with the Inveor drive control-

ler platform that is precisely adapted

to these requirements.”

“The modular design of Inveor

offers scope for many possible com-

binations, allowing industry-specific

applications to be implemented and

giving the customer the right solu-

tion for a given set of requirements.

The special feature of our Inveor plat-

With a power range from 0.25 kW,

it supplements this drive control-

ler family especially for applica-

tions in which lower motor ratings

need to be controlled for energy

efficiency. The other power ranges

from 0.37 kW to 22 kW are covered

by the Inveor with only four sizes.

Furthermore, all members of the

drive controller family are suitable

for the operation of asynchronous

and permanent magnet synchro-

nous motors. l

p Global 201436

KOSTALGERMANY

processes, without the user having

to deviate from his previously used

fieldbus system,” according to Vet-

ter. “This means that our company

philosophy of ‘Smart connections’

can also be experienced here. In this

way we on the one hand create ideal

connections between pump, motor

and automation, while at the same

time promoting smart connections

between companies and their cus-

tomers, as well as between product

and application solutions. Connec-

tions that are well thought-out and

oriented to success in the long run.”

www.kostal.de/industrie

common fieldbus systems, such as

Profibus, ProfiNET, EtherCAT and

CANopen. This enables easy inte-

gration into existing automation

features enable easy adjustment to

specific requirements.

“The entire Inveor platform

can also be equipped with many

Smartly connect people and machines

“The interface between human

and machine is extremely important.

But here too, the range of require-

ments is very broad,” says Vetter.

“They extend from minimal require-

ments with simple functions for sta-

ble handling directly on the device to

integration into guidance systems.

Against this background, we offer

completely varied human-machine

interfaces. Operation can take place

by means of a handheld controller

with clear display, either with an op-

tionally incorporated foil keypad or

via the proven PC software.”

As the most recent new devel-

opment, Kostal has introduced a new

colour touch screen terminal that al-

lows both intuitive and central oper-

ation, for example, of multiple pump

controls with one device. A variety of

kThe new interface

between human and pump

mAt the end of last year, at the SPS IPC Drives trade fair in Nuremberg, Kostal introduced the Inveor drive controller for the first time to round off the Inveor platform. With a power range from 0.25 kW, it supplements this drive controller family especially for applications in which lower motor ratings

need to be controlled for energy efficiency.

p Global 2014 37

KSBGERMANY

New mag-drive pump for process engineering applications

KSB launched the latest genera-

tion of its Magnochem mag-drive

pumps recently. Available in 52 siz-

es, the new series is primarily char-

acterised by high outputs per size

ensuring extremely low

energy consumption.

All pump character-

istics conform to the

ISO 2858/EN 22 858/

ISO 5199 standards.

The pumps’ en-

gineers have paid par-

ticular attention to the

design of the magnetic coupling and

the routing of circulation, cooling

and lubricating flows. This allows

the operator to choose between four

operating modes ranging from a sim-

ple internal circulation to a so-called

dead-end configuration with an aux-

iliary hydraulic system. As an option,

an external heat exchanger can be

installed. This means that the pump

set can be optimised for the pump-

ing of polymerising, coagulating and

crystallising as well as low-boiling

fluids.

The containment shrouds are

available in metals such as Has-

telloy or Titanium and can also be

made of zirconium oxide depend-

ing on customer requirements.

The latter is extremely resistant to

corrosion and does not produce

eddy currents when a magnetic field

passes through it. Unnecessary heat

losses which would reduce output

and compromise pump efficiency

are thus eliminated. The engineers

have selected samarium-cobalt as a

material for the magnets

mensioned rolling element bearings

as well as the environment from any

fluid escaping. The space around the

rotor can be monitored using sen-

sors.

Hydraulic couplings and pumps in stainless steel, titanium and much more.

UsEd iN SpacE

As well as the conventional ver-

sion in back pull-out design, a close-

coupled variant will be available in

44 sizes for installation in confined

spaces. The type series offers flow

rates up to 1,400 m3/h at a

maximum head of 233 m.

Permissible operating

temperatures range from

–90 °C to +300 °C.

www.ksb.com

as it is highly temperature-resistant

and has excellent magnetic charac-

teristics.

Diamond-coated plain bear-

ings ensure effective anti-seizure

properties in the event of insufficient

lubrication—a feature which, com-

bined with an optimised arrange-

ment of the radial plain bearings,

is particularly beneficial in ensuring

the pump’s operating reliability.

Multiple coupling dimensions are

available for each pump size, avoid-

ing the need for oversized magnetic

drives. The pumps feature very low

vibration levels during operation

as each pump rotor is subjected to

static and dynamic balancing in the

manufacturing process.

At the motor end, optional

leakage barriers such as shaft seal

rings offer an additional level of reli-

ability and protect the generously di-

p Global 201438

KTRGERMANY

Separated on purpose: New design of pump shaft coupling

Looking for some kind of technol-

ogy providing an easier assembly

even with couplings from grey cast

iron KTR faced a process that has

already proven successful in auto-

motive engineering. The result is an

innovative variation: the Rotex® S-H

with split hubs.

With the new design the hubs

are mechanically separated by

“cracking” on purpose. An uneven

surface with a positive fit is the result

making sure for an exact position of

the two halves during assembly. The

contoured, uneven cracked surfaces

ensure an ideal centering of the hub

halves. This guarantees that the hub

or the connection of the two hub

halves, respectively, is not weak-

ened by the separation by cracking.

The “cracked” hub is screwed in

place in block assembly and makes

sure that during operation there is

no negative impact on the strength

of the coupling. At the same time

the hub can be radially assembled

and disassembled without having

to disassemble the adjacent power

packs. The coupling is easy to access

and the adjacent components are

easy to be replaced: This makes sure

for a permanent availability of the

machine. The Rotex S-H with split

hubs is a low-cost shaft coupling

from grey cast iron that is easy to

service and well suitable for mount-

ing in narrow spaces. The coupling

is approved and certified according

to EC Standard 94/9/EG (ATEX 95),

category 2G/2D, and thus suitable

for applications in hazardous areas

of the zones 1, 2, 21 and 22. A wide

basic range is available in the sizes

38 to 90.

Easy retrofitting – requested by the user

One further advantage of this

coupling is the easy adjustment to

each individual application because

the pilot bored and “cracked” cou-

pling hub can be machined without

any extra costs. This feature guar-

antees the easy servicing of drive

components and systems requested

by the design engineers and mainte-

nance engineers without impacting

any technical parameters. In practice

the present drive systems are often

retrofitted with the new coupling

design.

www.ktr.com

mAs for the Rotex S-H with split hubs the hub can be radially assembled and disassembled

without disassembling the power packs—easier servicing.

p Global 2014 39

without difficulties by just one pump.

The versatility of the screw pump and

its use in low, medium and high-

pressure applications up to 100 bar

is a huge advantage. Pump speeds

of up to 3,500 rpm are acceptable,

depending on the individual appli-

cation. Screw pumps are found in

services like

l transfer pumps for different flow

rates and pressure

l loading/unloading pumps for

tanks/trucks/trains/ships/tank

barges

l circulation pumps (tank-to-tank

circulation/in-tank circulation)

l tank draining pumps/stripping

pumps

The pumping of stored and

refined oil products are done by

various pump types. Most familiar

for are double-flow, self-priming,

rotating positive-displacement twin-

screw pumps (l Fig. 2) having

Thomas Talarczyk

Oil and tank farm installa-tions (l Fig. 1) have ex-

perienced a real boom over the past few years. New tank farms are being built worldwide to cover the growing demand for crude and refined oil products. Innovative and more flexible pumping systems can make big contributions to a flexible, smooth and cost-efficient op-eration of oil and tank farms.

Apart from conventional centrif-

ugal and gear pumps, an increasing

number of screw pumps are being

used to transport stored oil products.

The big advantage is that oil products

with various qualities and viscosities,

different back pressures and suction

conditions such as presence of en-

trained air or gas can be pumped

LEISTRITZGERMANY

Frankfurt am Main · 15 – 19 June 2015

Be informed. Be inspired. Be there.

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➢ 3,800 Exhibitors from 50 Countries

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www.achema.de

Screw pumps in tank farmsScrew pumps in tank farms

mFig. 2 Double-flow, self-priming, rotating positive-displacement twin-screw pumps

p Global 201440

Innovative, operator friendly and energy efficient pumping systems

Over the past few years, the

focus in pump developments have

been on energy consumption, occu-

pational safety and reduction of op-

erating costs for the tank farm own-

ers and operators. The self-priming,

single-flow positive-dis-

placement

pumps with 2

or 5 spindle

profiles can also be used

to meet the new market require-

ments. These pumps are designed

Double-acting mechanical

seals with a barrier fluid system are

also used for applications where

longer periods of dry running can be

expected.

to over 10,000 cSt. Furthermore,

flow rates of up to 5,000 m³/h can

be transported with just one pump.

This type of positive-displacement

pump also allows for dry running

with fluids having low vapor pres-

sure and flashing

occurs when emp-

tying tanks or pipe-

lines.

totally four spindle profiles. These

pumps are axially and radially fully

balanced so as to avoid the need

of special thrust bearings and to

guarantee for long service life. The

flow is split when entering the pump

casing and transferred to each side

of the double flow spindle package

where it is pressurized to the com-

mon discharge. The rotors have to be

manufactured from one single piece

of material which eliminates the risk

of contact between the rotors and

casing.

This feature increases the

structural integrity and service

life of the spindles resulting in a

greater operational reliability. If

necessary a special modification

can be done to the spindle profile,

which leads to lower pump noise.

The drive spindle torque is trans-

ferred to the driven spindle via oil-

lubricated gears. This ensures an

operation of the pump without any

contact between the spindles and

the replaceable casing insert and

the spindle profiles themselves.

An important feature of this type of

pump is its ability to pump fluids

in the viscosity range from 0.4 cSt

LEISTRITZGERMANY

l

Fig. 1 Tank terminal

with loading arms (Source: Fotolia,

56206326 © Ralf Gosch)

lFig. 3 Single-flow,

self-priming positive- displacement pumps

so that the fluids are conveyed in an

axial direction with no pulsations.

This pump design ensures a greater

pumping efficiency with reduced

power consumption, as result, lead-

ing to lower cost of ownership, as

pump procurement cost as well is

low. It should also be pointed to

l

service life. What is special about

these pumps (l Fig. 3) is the fact

that the idler spindle is not driven by

gears. The torque is transmitted hy-

draulically by the flanks of the drive

spindle›s profile. The special profile

of the spindle ensures the perfect

closure of the pumping chambers

screw pumps. For example, the cas-

ing of these pumps is also in steel

with replaceable pump liner and

the spindles are made from a single

piece to ensure their structural integ-

rity. The pumps are also axially and

radially balanced eliminating trust

bearings, which guarantees a long

for a low-pressure operation of up to

16 bar (232 psi) and can transport a

wide variety of oil products, from low-

viscosity fluids such as “light” gas oil

(VGO) to high-viscosity asphalt and

bitumen. Fluids with a viscosity of

1 – 100,000 cSt with flowing tem-

peratures of up to 280 °C can

be pumped The flow rate goes

from a few litres per minute up to

1,700 m³/h depending on the pump

size selected. One common use of

these pumps is the circulation of

fluids for mixing and heating of vari-

ous oil products as well as transfer

and loading pumps.

Their design is similar to the

more familiar double-flow twin-

LEISTRITZGERMANY

The Best Partnership

w w w . l u t z - p u m p e n . d e

Professional Emptying of Drums and Containers

Lutz is the reliable partner in the fi eld of professional liquid

handling. As supplier of innovative and high quality pumps and

pump systems we support you in fi nding the best solution for

your fl uid handling requirements.

Lutz pumps are suitable for the complete drainage of drums

and containers, for mixing, and for pumping of thin and viscous

liquids, for easy infl ammable and explosive fl uids as well as for

acids, alkalis and oils.

For more information please contact us!Lutz Pumpen GmbH

P.O. Box 14 62

97864 Wertheim / Germany

Phone (+49 93 42) 8 79-0

Fax (+49 93 42) 87 94 04

e-mail: info@lutz-pumpen.de

Drum and Container Pumps Flow Meters Double Diaphragm Pumps Centrifugal Pumps

NEW

The new fl ow meter with touch screen display

Scan for product video

p Global 201442

ing conditions of operation. Another

advantage is that these pumps are

always self-priming. The change of

speed results in change of pump

flow which can be controlled au-

tomatically. This means that tanks

and pipelines can be quickly and

efficiently drained and stripped

using speed control to lower axial

velocities.

It is very important that the va-

pour pressure and NPSH are taken

into account when designing the

pumping system. The NPSH availa-

ble by the facility can be influenced

by several factors. In tanks with

a floating roof the liquid level can

only go down to a certain minimum

to change the cartridge or the

“pump’s entire internals” at the

time of service. The cartridge

is simply slid out of the pump

casing. A new cartridge can then

be slid back into the pump cas-

ing and the pump is ready for

operation again. The pump does

not have to be removed from

its base for this work. The pipe

connections on the inlet and

outlet side does not have to be

removed.

A single-flow or double-flow

positive-displacement pump with

variable speed control, on the other

hand, can cover wide and demand-

service work can be carried out

with less work and with smaller

and lighter components directly

on site, without the pumps hav-

ing to be brought to an external

shop.

l Less downtime for servicing

(longer running times): Only

pumps that are in operation

contribute to the operating

company’s profit. Thus, less

downtime during servicing

have a direct impact on the

company’s financial result.

Completely preassembled and

tested cartridge units are avail-

able to speed service work even

more. The operator only has

the biggest difference in design to

the double-flow twin-screw pump:

The mechanical seals to the atmos-

phere are reduced from four to only

one seal. In addition, the single-flow

positive-displacement pumps have

no separately oil-lubricated gears

or bearings. This permits the use of

single-action mechanical seals with

an oil quench on the atmospheric

side of the seal to ensure an oil film

is present between the rotating parts

of the seal when operating with neg-

ative suction pressure. Optionally, a

double-action mechanical seal can

be used. This seal should be pro-

vided with an external barrier system

that is included in the pump system

and supplies the mechanical seal

independently of the pumped fluid.

Simplified maintenance

When considering the aspects

of maintenance and service, the

single-flow pumps are very cost ef-

ficient and stand out positively. The

following bullet points really hold

true for these pumps.

l Fewer spare parts: An innova-

tive and parts-saving pump

design guarantees simplified

stocking of spare parts by the

operator or service contractor.

The operator can thus calculate

the benefits of an optimal stock

keeping of parts with a lower ser-

vice budget and capital tie-up.

l Simplified service and faster

overhaul: This means in the field

service! In the majority of cases,

LEISTRITZGERMANY

mFig. 4 Different pump applications in tank terminals

and the transfer rate can easily be

controlled by adjusting the pump

speed, protecting the receiving tank

from overfilling.

Circulation and blending

Screw pumps are also used to

mix oil products with different vis-

cosities in tank farms. A continuous,

pressure-independent pumping rate

using speed control is the guarantee

to achieve predetermined blending

ratios. This can be used particularly

for heavy oils blending with light

NAFTA or other light hydrocarbons

to produce a desired commercial

quality.

An increased production of very

heavy crude oils, bitumen, asphalt,

carbon black, pitch etc. is being sup-

plied to the global market. Purposely

built tank terminals and pump sta-

tions are required for trading these

products. Centrifugal pumps can-

not be used in these applications

due to poor efficiencies with high

viscosities and unpredictable op-

eration characteristics. The speed-

controlled, single-flow screw pump

as well as the double-flow, positive-

displacement twin-screw pump are

the reliable alternatives.

www.leistritz.com

without endangering the struc-

ture of the tank. That is normally

the lowest static liquid column or

pressure available. The pressure

drop from piping, strainers and

valves then has to be deducted

from this value. The vapour pres-

sure and specific weight at a given

liquid temperature are further cor-

rections. The pump has to be able

to operate under such conditions

which is referred to as the lowest

NPSH available operating point at a

given viscosity.

Of these variables, the relation-

ship between vapor pressure and

temperature is the biggest element

of uncertainty. Screw pumps, and

in particular single-flow positive-

displacement pumps are designed

to operate with very low NPSH avail-

able., The risk of cavitation, vibration

and vapor locking is greatly reduced

and the operator can fully exploit the

inherent properties of these pumps

to his advantage.

Loading and unloading

In tank terminals for ship load-

ing, large volumes of oil products

must be transferred in the shortest

possible time. The pumps have to

be able to operate quickly and reli-

ably. That is also the case in bunker

stations or bunker ships or barges.

The single-flow screw pump is ideal

for this service. It can be installed

vertically in the tank or on deck to

save space. The flow rate is practi-

cally independent of backpressure

LEISTRITZGERMANY

INDIVIDUAL AND EFFICIENT

S I M P LY A C L A S S B E T T E R :

Powerful: Type SM – waste water pump.

Extreme wear resistant: Type FB

Intelligent Concept: Type SZCUT

p Global 201444

LEWAGERMANY

New plunger pumps with drive powers of up to 800 kW

Plunger pumps according to API 674 are used wherever high hydraulic

power is needed, especially in the oil and gas sector and the process in-

dustry. These pumps are characterized by their compact construction and

low weight, which is particularly significant for offshore installations. To

meet the special requirements of customers even better, Lewa now offers a

new generation of pumps with splitted gear housings. This special feature

significantly facilitates maintenance, permitting the use of a fully balanced

crankshaft which generates less noise and vibration, thus reducing wear.

The power range was also extended with two quintuplex plunger pumps.

unit is self-adjusting and both the

crankshaft and the pinion shaft are

practically free of axial load.

These plunger pumps are very

powerful and work with volumetric

accuracy. Their large valve cross-

sections make the suction pres-

sures required comparatively small.

This mostly eliminates the need of a

booster pump. Starting at a power of

15 kW, flexible use is possible at dif-

ferent drive speeds up to 800 kW, at

pressures of up to 3,500 bar and a

maximum flow rate of 290 m3. They

are especially used for uncritical

fluids like glycol, methanol, or

inhibitors that are

similar to water in terms of their vis-

cosity.

Now both quintuplex variants,

the G5K 500 and G5K 800, are avail-

able with maximum power of up to

800 kW. By increasing the number of

plungers, the size of the individual

components can be reduced for the

same hydraulic power. That leads

to a reduction in weight, in turn fa-

cilitating maintenance. They also

achieve a low residual pulsation of

about seven percent, thanks to the

five plungers.

Simple maintenance and great flexibility

To protect the gear unit from

low oil levels and excessive tem-

peratures, the pump is monitored

by default by a temperature and

pressure switch. In the oil and gas

industry, this is often implemented

using transmitters. Within the gear

housing, the crosshead pins and

plain bearings are supplied by an

integrated pressure oil lubrication

system, so no additional systems

are required. Because all the oil

seals are accessible from outside, no

gear oil needs to be drained during

maintenance tasks, which has a ben-

eficial effect on downtime. The pump

head is equipped with an innovative

plunger seal. Pressure and/or spring

support of the seal packing allows a

long service life and high availability.

The gland packing is entirely mainte-

nance-free; it never requires adjust-

ment of pretensioning or repacking.

Any packing leaks are returned inter-

nally, so no external pump is needed

for returning the leakage back into

the suction line and no monitoring

is necessary.

Due to the modular construc-

tion, a pump can be configured that

meets the requirements resulting

from the application. Different pump

head designs and valves are avail-

able for this purpose. The pump

head design makes it possible to

exchange the conversion kit, that is,

the plunger and stuffing box, thus

adjusting the volume conveyed and

the discharge pressure over a cer-

tain range. All pumps are optimized

for operation with speed controlled

electric motors and/or diesel en-

gines, but of course they can also

be operated without a frequency

converter. The maximum regulation

range is between ten and one hun-

dred percent of the rated speed. De-

pending on the application and/or

the fluid, a wide variety of materials

is available for selection. A number

of different connection geometries

and several options for monitoring

and flushing are also offered.

www.lewa.com

The very short design of these

plunger pumps is made possible by

the special alignment of the plunger

and crosshead. These pumps also

have outstanding efficiency, low

energy consumption, and a long

service life. The new structure with

the splitted gear housing and the

fully balanced crankshaft doesn’t

just reduce wear, but also particu-

larly facilitates maintenance. The

design of the pump also permits the

maintenance of components without

disassembling the process pipeline.

The crankshafts are drop-forged and

shot-blasted, leading to a homoge-

neous grain structure and low

stress level. The

integrated gear

kThe divided gear housing of the new

quintuplex pump permits the use of a fully balanced crankshaft and facilitates maintenance.

All versions of the dosing pump series

Memdos Smart are equipped with a hybrid

stepper motor with improved efficiency as

an electrical drive. The speed can be regu-

lated with a very high resolution through

microprocessor-controlled current feed of

the stepper motor in conjunction with a per-

manent sensor-assisted position monitor.

The power is transferred via a maintenance-

free tooth belt drive. This produces vibration-

free power transfer and a positive diaphragm

guide, enabling extremely high level of preci-

sion in the reproducibility of the individual

strokes.

The nature and version of dynamic

stepper motors enable individual suction

and pressure strokes with various speeds.

This “asynchronous” delivery characteristic

means that the speed in the suction stroke

remains constant with reduced delivery ca-

pacity and the speed in the pressure stroke

is reduced. With small delivery capacities,

this results in especially low-pulsation, an

extended pressure stroke and thus a ho-

mogeneous dosage. After a stop, the pump

approaches a defined start position, which

serves to avoid misdosing.

A diverse range of alternatives for every need

The pumps of the Memdos-Smart se-

ries are available in four control and equip-

ment versions LB, LD LK and LP. All control

versions come fitted with a long-range power

supply unit and can be operated in power

networks in the range 110–240 V and 50/60 Hz. The

housings are implemented in the protection class

IP65. The mechanical connection of external inputs

and output signals is effected via a robust standard

M12x1 screw connection in various dopings in order

to avoid inversion and thus damage to the pump.

In the control version LB, the Memdos Smart is

equipped with a revolution potentiometer for setting

Excellent Pump Technology for international Markets

Minerals & Mining | Power & Energy | Oil & Gas Chemical Industry | Food & Pharmacy

FELUWA Applications:Aggressive, abrasive and toxic Media | Hydrotransportation Autoclave/Digestor Feeding | Fly and Bottom Ash Disposal Coal Gasification | Pipeline Transportation | Reactor Feeding Wet Oxidation | Tailings Transfer | Hygienic Design | Dewatering

FELUWA MULTISAFE Double Hose-Diaphragm PumpsFlow rate up to 1000 m3/h Pressure up to 500 bar

FELUWA.COMEngineered and Made in Germany

LUTZ-JESCOGERMANY

Dosing pump with microprocessor- controlled stepper motor drive

p Global 201446

the delivery capacity in the range 0–100 %. Two

LEDs on the operating panel provide information

about the current pump condition. The release in-

put can be used to start and stop the pump from

an external location such as an PLC. In addition,

the pump can be calibrated to adapt it to local

conditions.

The Memdos Smart LD is fitted with a full-

graphical display and four multi-function

push buttons as a control unit. This

enables the delivery capacity to be set

in fine stages between 0–100 % using

a visualised bar. This pulse input can

be fitted with a pulse increase

and reduction. In addition to

the release input, this dosing

pump can be evaluated with

a pre and main alarm signal

e. g. a suction lance with level

switch.

The Memdos Smart LK comes

equipped with all the features of the LD

control version; plus the graphic display

of this version displays the delivery capac-

ity in clear text and as a percentual value. The

delivery capacity can be altered in 0.1 %

increments. The well laid-out menu,

reminiscent of a mobile telephone ena-

bles the user to change the language and delivery

units. The pump can be secured against inadvert-

ent interventions through the setting of a release

and safety code. The slow motion mode enables

the safe dosing of even viscous media. To this end,

the speed of the suction stroke is reduced. The

diaphragm can be changed in a special program

which advances it to the fore end position. An inte-

grated “alarm relay” switches the output foreseen

for a malfunction scenario. The stroke feedback

output provides a further monitoring method; the

pump issues a signal at the output following every

stroke.

The Memdos Smart LP is equipped with

the most developed control. In addition to the

features provided by the LK, the LP provides an

added bonus in terms of convenient functions

and possible connections. Thus in addition to

the above mentioned pulse input, the LP has

an input for analogue signals. These can

be processed in the range from 0/4–10 mA. Es-

tablishing an “analogue profile” enables adapta-

tion of the analogue input to local conditions. The

pumps can additionally be deployed in “batch

mode”. The previously-programmed batches can

be started by various events – manually, by an

external digital signal, an internally-set interval

or an integrated week/day timer permitting two

start times. The slow-motion mode is performed

in two stages; stage 2 reduces the suction stroke

speed once again. Optionally, the LP is available

with a “diaphragm rupture recognition” feature;

the sensor signal is evaluated pump internally.

The ever-increasing integration and networking of

the components in industrial process engineering

processes are catered for by an optionally-avail-

able net version. This is equipped with an

additional industrial Ethernet connec-

tion port, which can be integrated

in an existing field bus network.

The supported communication

protocol is Modbus TCP.

Material diversity and a wide range of accessories

All versions of this dosing pump

series are available in the four materi-

als PP, PVC, PVDF and stainless steel. The

provisions are rounded off by a specially-

designed range of accessories adapted to

local conditions. They are available in four

delivery capacities with 5, 10, 15 and 20 l/h.

The maximum working counter-pressure ranges

from max. 15 bar (5 L version) to max. 4 bar (20 L

version).

www.lutz-jesco.de

LUTZ-JESCOGERMANY

multi-function

ol unit. This

y to be set

00 % using

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hic display

elivery capac-

ntual value. The

red in 0.1 %

out menu,

phone ena-

anguage and delivery

added bonus in terms of convenient functions

and possible connections. Thus in addition to

the above mentioned pulse input, the LP has

an input for analogue signals. These can

the sensor signal is ev

The ever-increasing inte

the components in indu

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developed control

20 years pThank you for your

confidence

p Global 2014 47

MOTIVEITALY

Solar panels drive pumps

Neo Solar is a new patented inverter

whose power is directly supplied by

solar panels (without tension sta-

bilizer and batteries in the middle)

or hybrid (solar panels and power

net simultaneously), for AC pumps

(l Fig. 1). Neo Solar permits to set

the pump speed.

It can be mounted directly onto

the AC motor or onto a wall, with-

out any need to mount a protection

cabin, thanks to its IP65 protection

index.

If needed, its WiFi keypad per-

mits to control the pump in those

places where it is difficult to reach it.

Advanced software improves the cur-

rent supply to the motor compared to

a classic MPPT system.

The system can work in two ways:

l island: without any connection

to a power grid (l Fig. 2)

l hybrid solar/net: automatically

and proportionally it will use the

available solar energy and, if not

enough, it will compensate the

balance with the energy com-

ing from the net or a generator

(l Fig. 3).

Neo Solar can work with a wider

number of pumps that are already

installed, since these are normally

with AC motors, without any need to

replace the pump. AC motors are in

fact the most used on pumps, they

are more economic and they can

reach premium efficiencies (IE3).

The installation and the main-

tenance of these systems is known

and accessible for all technicians

worldwide (l Fig. 4). Compared to

DC pumps the current is lower, the

cables are of thinner section, and

there are less cable losses. The pow-

er goes up to 22 kW.

www.motive.it

m nFig. 4 Fig. 3

Fig. 2

lFig. 1

p Global 201448

Working in extreme conditions in an African oilfield

oil companies, with the conveyance

of the black gold, which is distributed

across different deposits. The oil,

still in its untreated state, was to be

taken from these to central treatment

facilities (CTFs) and then around

1,300 km further to Port Sudan via a

pipeline with six conveying stations.

Certainly, bridging the first transport

section from the borehole to the CTF

is problematic, since the composition

of the crude medium being conveyed

is constantly changing.

Above all, high proportions of

gas and sand can lead to convey-

ance failures, pressure losses and

equipment damage on various types

of pump in the process. The Nemo®

progressing cavity pumps manufac-

tured by Netzsch can cope with these

difficult conditions without suffering

any damage. At the request of the

operating consortium, the business

field oil & gas special pumps team

developed a solution which was tai-

lored to the specific starting point.

Extreme working environment: sand-storms, downpours, scorching heat

Firstly, 20 multiphase pumps

were divided up into several blocks,

each of which is designed to take up

the output from up to 24 oil wells

and to convey it to the nearest treat-

ment plant. The stretches which had

to be negotiated in the process are

sometimes 15 km long with an am-

bient temperature of up to 50 °C and

surface temperatures of up to 70 °C.

In order to reduce the risk of damage

and the maintenance workload as

far as possible in view of the remote-

ness of the location, the pumps were

mounted on skids, so that they are

not standing in water when it rains.

A simple sunroof provides protection

from too much heat. In addition, out

of the wide range of available joint

options, the choice was made to use

Z pivot joints, as these stand out due

to their being particularly robust.

The pump system itself is

based on progressing cavity tech-

nology. A helix rotor rotates within a

helix stator, so as to form conveying

chambers which move from the inlet

to the discharge side with the rota-

tion. In this way, hardly any shear

Working in extreme conditions in an African oilfield

Thomas Böhme

An estimated 900 million barrels

lie under the Palogue Oilfield, the

largest in the rift valley area, south

of the Sudanese capital, Khartoum.

2005 saw the start of PetroDar, an

international consortium of various

NETZSCH PUMPS & SYSTEMSGERMANY

kThomas Böhme

pumps, which had to transport extremely large quan-

tities of sand in the pumped material, meaning that

these components had to be replaced. On the other

hand, many of the pumps which were not used in

such particular load phases are still running with the

original stator, in spite of the hard working environ-

ment and the difficult conveyance conditions.

www.netzsch.com

than eight years in the Melut Basin. The developers

asked the operators about their experiences so far

and checked the condition of the equipment, which

had been running without any significant problems

up to that point. Above all the pivot joints proved

themselves over sustained use: since then no main-

tenance work has been needed either on the joints,

the drive chain or the bearing housing. Wear had only

occurred on the stators and mechanical seals of some

forces or pulsation arise and the unwanted

emulsion formation with oil-water mixtures

is avoided. In addition, the flow rate for this

process remains stable, even with high pro-

portions of sand or gas – an important as-

pect for the fields in the Melut Basin, as the

gas-oil ratio (GOR) here can be 50 SCFD per

barrel. In order to be able to cope with pump-

ing capacities which are sometimes very

high, one of the largest multiphase pumps in

the NetzschH product range was used, with

an output of 250 m³ per hour.

Hardly any maintenance work in spite of continuous operation

The whole order was manufactured

and delivered within three months. As well

as the oil pumps, the scope of delivery also

included the drive systems, including the

control system, filters for the inlet basket,

stop valves, check valves and relief valves,

along with return pipework and lubrication

injection pumps. As time was short, the

first of the pumps weighing up to 10 t were

flown to Sudan specifically with an Antonov

AN-124, one of the largest transport aircraft

in the world, while the remaining ones were

transported by sea.

Since then the 20 multiphase pumps

have been providing their service for more

k

These multiphase pumps,

which are specialised in the

conveyance of oil-sand-water

mixtures, have to cope with an

oil-gas ratio of up to 50 SCFD

per barrel in the Sudanese

oil fields.

NETZSCH PUMPS & SYSTEMSGERMANY

Talweg 12 · D-75433 Maulbronn · Tel. +49 (0)7043 101-0info@flux-pumpen.de · www.flux-pumpen.de

Now independent and free.The motor FBM-B 3100 is the world‘s first brushless and therefore maintenance-free battery motor for pumps. In combination with the small sealless COMBIFLUX drum pump it is impressive with a high delivery rate, astonishing for such a small pump. With its replaceable storage battery it is extremely usefull wherever electrical outlets and cables are not desired and ideal for outdoor works – leaving you independent and free.

We deliver values.

e he

gh eable s and u

p Global 201450

Diamonds from the microwave

PFEIFFER VACUUMGERMANY

Diamonds are typically pro-

duced under gigantic pressure

and under enormous heat. Natural

diamonds were formed thousands

of years ago inside the Earth at a

depth of 150 km and a tempera-

ture of 1,400 °C. They consist of

carbon, condensed at a pressure of

over 70,000 kilograms per square

centimetre. During a volcanic erup-

tion, the diamonds pass through the

Earth’s crust to its surface, where

they are deposited in volcanic rock.

The Earth’s diamond reserves

are limited and excavation often

takes place under difficult condi-

tions. Global production of natural

diamonds is currently at about 20

tons per year. Only five percent of the

stones found are of jewellery qual-

ity. The remainder is used industri-

ally, for example, for drills and tools.

However, the demand for commer-

cially viable diamonds is far greater

than the supply. Natural diamonds

cannot meet about 80 percent of

industrial demand. In order to close

this gap in demand and to produce

material for specific applications,

the synthesis of diamonds continues

to gain in importance. A particularly

efficient process for the synthetic

production of diamonds has been

developed by Dr. Hildegard Sung-

Spitzl and her husband Dr. Ralf Spitzl

from the Iplas company in Troisdorf,

Germany. For this method, the valu-

able gemstone is manufactured from

a gas mixture in a microwave-excited

plasma source.

Use and properties of synthetic diamonds

The most well-known prop-

erty of diamonds is certainly their

hardness, which exceeds that of all

other materials. The range of specific

technical properties, however, is sig-

nificantly wider and ranges from the

highest degree of heat conductivity

through good electrical insulation to

an extremely high optical refractive

index and high chemical resistance.

A flawless diamond grows in a vacuum

Chemical vapour deposition

(CVD) is an extremely efficient pro-

cess, even making it possible to

produce the metastable diamond.

In a vacuum chamber, hydrogen and

methane are chemically reacted in a

microwave plasma at a pressure of

several hundred hPa. Individual

atoms can be separated from the ex-

cited molecules until highly reactive

compounds remain, from which the

coating is formed.

The growth process is carried

out on wafers or so-called “seeds”

consisting of a correctly oriented

diamond disc. The excited carbon

from the plasma is deposited on the

surface. The excited hydrogen in the

plasma ensures that only the carbon

in the diamond compound (sp3) re-

mains; resulting graphite, however,

is removed immediately.

Due to the high efficiency of

the process, layers several milli-

metres thick can be manufactured

in a few days, which creates suf-

ficient material to also create

jewellery diamonds. As the entire

process chain consists of over 50

individual steps, the highest pos-

sible degree of process safety in

the coating process is essential for

commercial uses.

Diamonds from the microwave

lFig. 1 The core of the

plasma system is a flat steel cylinder with elaborate fine holes through which the gas

enters. In the interior, the gas transformed into a plasma

state gives off light.

p Global 2014 51

products have since been success-

fully scaled to the nascent series sys-

tems and transferred to them.

Pfeiffer Vacuum supplies Iplas

with all necessary vacuum compo-

nents and pumps. The products

used are from Pfeiffer Vacuum’s ex-

tensive standard portfolio. Pfeiffer

Vacuum with its years of experience

in these applications supported the

project in all its planning and design

stages right from the initial project

planning phase.

www.pfeiffer-vacuum.de

of the vacuum performance values.

All specifications that had previously

been achieved in the first develop-

ment system using Pfeiffer Vacuum

Vacuum DuoLine series rotary

vane pump. The plasma process is

pressure-regulated. Here, a Pfeiffer

Vacuum TPR 280 Pirani gauge is

used. When designing the plant,

the pumps were intentionally over-

dimensioned in order to increase the

reliability and the durability of the

industrial process. When selecting

the vacuum pumps and the compo-

nents, Iplas placed high value on the

high quality of the products as well

as the high degree of reproducibility

PFEIFFER VACUUMGERMANY

Pfeiffer Vacuum’s vacuum solution

To manufacture the gemstones,

an environment as free of particles

as possible is needed. The smallest

impurities will influence the quality

of the diamonds grown. For this rea-

son, synthesis generally takes place

in the pressure range from 100 to

300 hPa.

The vacuum required for the

process is generated using a Pfeiffer

mFig. 2 The wafers on which the diamond will grow in plasma can be seen on the right.

In the middle, the graphite separating from the gas mixture is shown. The cut, synthetically produced diamonds can be seen on the left.

Many years of experience coupled with state-of-the-art technologies enable the

to set technological standards!

Many years of experience coupled with state-of-the-art technologies enable the state-of-the-art

o set technological standarardsds!!to

100% C O AT I N G M E A N S 0% C O R R O S I O N !

We have invested a big deal in the new anti-corrosion pump:

2,000,000 EUR development costs, 5,500 days of development,

1,500 test facility measurements, 400 foundry models. All to achieve one aim: 100% corrosions protection in pool water.

Herborner Pumpen – number 1 concerning swimming pool pumps.

J.H. Hoffmann GmbH & Co. KG | Littau 3-5 | 35745 Herborn, Germany | Telephone: +49 (0) 27 72 / 933-0Fax: +49 (0) 27 72 / 933-100 | E-mail: info@herborner-pumpen.de | www.herborner-pumpen.de

nFig. 3 The vacuum required for the process is generated

by DuoLine

p Global 201452

PROMINENTGERMANY

When it comes to extracting

gas at a depth of around

70 metres off the Arabian Pen-

insula near the North Field, the

world’s largest gas reserve at over

544 square kilometres, quality and

reliability are essential. Process

metering pumps play a key role in

ensuring that the gas is extract-

ed safely. A total of 230 process

metering pumps were supplied by

ProMinent.

In the Khuff Formation off the

Arabian Peninsula, production is

currently 250,000 bpd (barrels per

day) for oil, 30,000 bpd for conden-

sate, 200 MMScf (Million Stand-

ard Cubic Feet) of carrier gas and

600 MMScf of natural gas. A high

hydrogen sulphide content makes

extraction of the natural gas difficult.

The pipelines need to be protected

against this aggressive, corrosive

substance. Different components

also need to be extracted. A total

of 230 ProMinent process metering

pumps are used for both purposes,

ensuring that precise quantities of

corrosion inhibitors and methanol

are added to the crude oil mix.

180 process metering pumps ensure corrosion protection

Hydrogen sulphide can pro-

duce very corrosive acids, which can

corrode even stainless steel pipes

– to the point of pitting. Once the

pipes have holes in them, the scale

of damage is huge – not just for

the environment but also in finan-

cial terms as extraction has to be

stopped when leaks arise. The as-

sociated costs then quickly become

six-figure sums.

To prevent this from happen-

ing, corrosion inhibitors are added to

the gas. A corrosion inhibitor binds

oxygen, produces a protective layer

on the inside of the piping and also

prevents the formation of corrosive

compounds. Precise metering is very

important because metering either

too much or too little would result in

an even higher risk of corrosion. So

ProMinent delivered 180 hydraulic

diaphragm metering pumps from

the Mh2S 35/8-8 product range.

Designed for a maximum pressure

of 630 bar and pump capacities of

up to 2 x 12.1 l/h at 200 strokes

per hour, they are used to meter the

corrosion inhibitors.

50 process metering pumps ensure precise extraction

Another application in the

Khuff reservoir is the precise me-

tering of methanol. For this task

the customer also opted for reli-

able process metering pumps from

ProMinent®. Methanol is used in

the chemical and oil industry as

an extracting agent, for example to

separate aromatic and paraffinic

hydrocarbons. Injected at high pres-

sure, it also prevents hydrate forma-

tion at the point of gas extraction.

Reliable hydraulic diaphragm pumps

from ProMinent are used to ensure

that the methanol is injected evenly

and in the correct amount. The Hei-

Process meter

pressures r

Hydraulic diaphragm metering pump from the Mh2S 600/28-28

product range

qHydraulic metering pumps from the

Mh2S 35/8-8 product range

PROMINENTGERMANY

53p Global 2014

very accurate metering possible. The

specifications of the American Petro-

leum Institute (API) serve as one of

the most important guidelines for re-

fineries and the oil and gas industry.

To ensure high operational

reliability, the pump heads are

equipped with double stainless steel

diaphragms. Additional features in-

anti-cavitation of hydraulic leakage

is wear-free and guarantees an opti-

mum dosing precision of +/– 0.5 %.

The suction and discharge valves are

designed for the nominal width and

the applicable operating pressure up

to a maximum of 630 bar. All parts in

contact with products are made of

stainless steel.

application are equipped with two

hydraulic diaphragm pump heads

and are designed to operate in a tem-

perature range of – 40°C to + 200 °C.

A metal diaphragm hermetically

seals off the product space from the

hydraulic section. During the com-

pression and suction strokes, the

diaphragm is moved by the hydrau-

lic medium which is compressed by

the piston. A relief valve as well as

an automatic bleed valve for the hy-

draulic chamber are integrated in the

pump head. The valveless enforced

delberg-based manufacturer deliv-

ered 50 hydraulic metering pumps

from the Mh2S 600/28-28 product

range. They are designed for a maxi-

mum pressure of 630 bar and pump

capacities of up to 2x 130 l/h at

182 strokes per hour.

Good operational reliability and availability

The hydraulic diaphragm me-

tering pumps Mh2S used for this

ing pumps for

of up to 630 bar

m180 hydraulic metering pumps from the Mh2S 35/8-8 product range are

awaiting dispatch

ProMinent process metering

pumps are designed in accordance

with API 675. Their compression-

rigid characteristic curve makes

clude very low-wear operation and

the assembly of the pump heads

without special tools.

www.prominent.com

Hydraulic couplings and pumps in stainless steel, titanium and much more.

SPacE agE TEchNology

p Global 201454

Total encasement for aggressive conditions

RENNERGERMANY

l Even the most powerful pump

won’t help when corrosion

and wear compromise its avail-

ability.

l A motor may still be well-

painted or coated – but in

aggressive environments just a

tiny scratch is enough for metal

parts to start corroding that is

hardly stoppable.

To prevent corrosion, especially in

wetted pump components, differ-

ent plastics are used not only in the

chemical, but also pharmaceutical

industry, including environmental

and process engineering. However,

such measures do not provide 100 %

protection in an aggressive operat-

ing environment.

First of all, bolted joints, ribs

and open shaft passages are af-

fected by aggressive environments.

But even the housing of ventilated

pump motors is at risk. Here the risk

is from the cooling flow itself. This

sucks the vapors from the ambient

air and blows it out to cool the mo-

tor along the motor housing. In acidic

or salty atmospheres, this leads to

additional external corrosion.

And last but not least, very or-

dinary dirt gets accumulated in the

pumps, because if the fan guard,

fan blades and the ribbing of the

motor housing are not cleaned regu-

larly, the accumulating dust reduces

air flow and gradually blocks these

completely at some point of time. And

the result is that the motor is over-

heated and susceptible to failures.

100% total protection

In this respect, Renner en-

terprise goes one step further and

equips the complete pump, in-

cluding drive motor, with a plastic

encasement. Corrosion and dirt are

kept outside in the same way, while

the life of the pump is extended sig-

nificantly. The non-vented housing

also ensures a quieter running and,

thanks to its smooth surfaces, allows

cleaning through spraying.

Even more important than

these rather aesthetic factors is the

high overall efficiency of the com-

pact assembled pumps. Renner

succeeded in increasing the pump

efficiency by an additional 10 %

through design improvements, re-

sulting in an optimized nearly 25 %

overall efficiency together with a

motor efficiency which is improved

by around 15 %.

Due to the additional equip-

ment with a frequency converter, the

pump velocity can be controlled and

thus adjusted to the operating point

required in each case. Since the

power consumption of a centrifugal

pump increases or drops with the

cube of the speed according to the

affinity law even small differences

are noticeable. In other words: the

power consumption is considerably

lower at reduced speed. Through

automatic adjustment of pump per-

formance to the changing transport

needs in the system and with the

help of an efficient motor technology

up to 40 % of the drive energy can be

saved compared to a conventionally

operated pump.

Highly efficient motors

Even today Renner complies

with the EU-efficiency demands of

2015 and 2017 in a large number

of drives used. Optionally with the

IE2 or IE3 asynchronous motors, the

company offers innovative synchro-

nous motors (permanent magnet

motor), with which the power dissi-

pation can be reduced again by 5 to

10 % compared to IE3 motors.

Motors from our own produc-

tion are used in submersible cen-

trifugal pumps as well as in mag-

netically coupled centrifugal pumps.

These motors are an integral part of

a holistic approach and especially

developed modular system by which

Renner implements application-spe-

cific solutions with pinpoint accuracy

thanks to its high production depth.

www.renner-pumpen.de

mCorroded metal parts of electric motors despite

acid-resistant two-component painting, in use in chemical

industry

kNew, highly efficient centrifugal

pump made of plastic with complete plastic encasement

and fan-less drive.

p Global 2014 55

SCHMALENBERGERGERMANY

The new centrifugal pump SMK with its flow

optimized pump casing is made of high-

performance synthetic fibre. The SMK pumps

fluids and gas mixtures with air inclusions

up to 15 %. The pump is self priming up to

3 m and operates in snore installation. With

its low weight and compact design the SMK

operates on a low noise level due to the vi-

bration reducing pump support. In addition

to the high hydraulic efficiency it can be oper-

ated with integrated frequency converter for

variable speed.

The Safe and Protect System PumpCon-

trol from Schmalenberger against dry running

of the mechanical seal, is available on request

for an individually configuration.

www.schmalenberger.de

Moving Energy Forward

Ideal solutions for off shore, upstream, midstream and downstream

As an expert manufacturer of downhole and surface pumps, we produce oilfi eld pump systems according to the highest quality standards. The viscosity of your crude oil or its percentage of gas or sand makes no diff erence to the NETZSCH progressing cavity pumps, our helical rotor system is unbeatable.

NETZSCH Pumpen & Systeme GmbH

Business Field Oil & GasGeretsrieder Str. 184478 WaldkraiburgGermanyTel.: +49 8638 63-0Fax: +49 8638 67981info.nps@netzsch.comwww.netzsch.com

New selfpriming centrifugal

pump

News, facts, developements about

pumps + systems

www.delta-p- online.com

p Global 201456

SEROGERMANY

8.5 GPM @ 3.300 ft TDH and

a NPSHR of 10 inchesActual these raw data are generated

by a centrifugal pump and seem to

set new records. SHP, as the new

high pressure pump is called, is

manufactured by the German side

channel pump specialist Sero Pum-

pSystems GmbH, which has more

than 80 years of experiences in this

niche area.

Low flow rates and high de-

livery heads – this is what the side

channel pump is made for. It com-

bines the advantages of positive

displacement pumps and centrifugal

pumps by positioning between both

operating-fields (flow vs. head). In

extreme cases, even about 4.4 GPM

at 3,500 ft and 9 inches NPSH is

possible. Furthermore, the unique-

ness of the SHP is established by

handling up to 30 % entrained gas or

vapor. That makes the side channel

pump predestinated for operating it

close to the vapor pressure curve of

different fluids – at lowest suction

heads. According to this, the handle

of liquefied hydrocarbons and other

low boilers with the SHP saves cost

due to the equipment layout which

doesn’t need high differences in

geodetic altitude and makes energy

intensive chillers redundant.

The construction of this new

pump is especially remarkable as

well due to its development for the

requirements of the American refin-

ery standard API 610, correspond-

ing with international standard

ISO 13709, in which side channel

pumps aren´t mentioned explicitly.

Nevertheless, the engineers

did a good job and succeeded by

transacting most standard guide-

lines (some deviations had to be ex-

pected), and opened the market for

the Oil & Gas Industry for intelligent

and reliable side channel solutions.

Based on this, these side channel

pumps are the answer for hydrocar-

bon condensate, LPG and NGL appli-

cations like flare knock out-, scrub-

ber bottoms- or crude oil pumps.

The SHP, developed as a

multistage segment-pump owns a

second barrel which encloses the

H-P-hydraulic, so it is designed for

top safety demands (Fig. 1). It is con-

figurable from one to eight stages

8.5 GPM @ 3.300 ft TDH and

a NPSHR of 10 inches

kFig. 1

kFig. 2

SEROGERMANY

of any popular make and ending up

with specialized single- and double

action 1,450 PSI mechanical seals.

Preparing for the future, the Sero

engineering team is currently work-

ing on a sealless SHP-version with a

magnetic drive according to API 685

– so further records are guaranteed!

www.seroweb.de

compensated by a balance drum, as

unlike other high pressure pumps.

The MAWP of the casing is

1,450 PSI, according to the capabil-

ity of the high pressure hydraulic.

However the shaft sealing can be

chosen very flexible corresponding

with the customer’s specific require-

ments, setting in with ordinary in-

dustry cartridges, API 682-cartridges

3600 RPM) is allowed; the pump

follows the affinity laws – a higher

speed is not required to reach high-

est heads.

Actually the eight-stage version

of the SHP needs, thanks to its con-

struction method, only about 14 ft²

of ground. This small sized footprint

saves lots of space and cost not only

because it makes the design and

construction really simple, but also

because the hydraulic doesn’t cre-

ate an axial thrust which needs to be

and available in different steel and

chrome steel qualities, aside from

austenitic stainless steel (API-mate-

rial class: S-6, S-8, C-6, A-8). In com-

bination with one classic centrifugal

impeller at the intake, the patented

side channel casing generates the

extremely low suction head (NPSH),

one special feature of the SHP.

Due to the steep and linear

characteristics (Fig. 2), the SHP is

easy to control by the differential

pressure. A wide speed range (900–

mFig. 3

Pumps and Valves - Experience, Responsibility, Passion.

www.klaus-union.com

made in Germany

p Global 201458

STERLING SIHIGERMANY

Looking at the life cycle costs of

rotating machines, it is clear that,

in addition to energy costs, service

and maintenance costs present the

greatest source of savings potential.

The goal here is to reduce service

and maintenance costs through the

use of efficient and intelligent con-

dition monitoring systems and to

avoid high costs due to production

downtime.

Requirements for innovative

condition monitoring systems

l Detection of unacceptable

operating conditions

l Online monitoring

l Universal use for many applica-

tions

l Easy usage

l Simple integration into distri-

buted control systems

l Low cost, or reasonable cost ratio

Vibration analysis is the most

universal method for condition moni-

toring of machines, since a number

of impermissible operating states

can be detected, such as unbalance,

misalignment, pipeline forces, bear-

ing wear, coupling wear, cavitation,

exceeding maximal flow rate, me-

chanical friction, loose mechanical

parts, etc.

The Sihidetect sensor measures

vibration velocity and accele ration

every 30 seconds (over 1,000,000

measurements per year). Through the

intelligent evaluation of this data with

the defined boundary values as per

DIN/ISO 10816, the machine’s condi-

tion can be displayed via integrated

LEDs. Furthermore, instances of

boundary values being exceeded are

logged in the sensor’s error memory.

The following operation conditions

can be detected:

l Unbalance

l Maximum flow exceeded

l Misalignment of pump and drive

l Mechanical friction of rotating

components

l Pipeline forces

l Loose mechanical components

l Bearing wear

l Magnetic coupling de-synchro-

nisation

l Coupling wear

l Resonance frequencies

l Cavitation

l Fluid noise

Can be used anywhere

l All rotating machines with a

speed >240 rpm

l For applications in non-hazard-

ous and hazardous areas

l Power supply 11 – 30 V DC

l 4 – 20 mA HART® current

interface

l Can be used at up to 160/80°C

Due to its low investment costs

and simple installation, the sensor is

a highly cost-efficient alternative to

hand-held vibration measurements.

For just € 14 per month (investment

costs over four years), rotating ma-

chines can be monitored online.

The basic component of each

online condition monitoring system

is the sensor that is attached to

m

The compact sensor can be used for installations in non-hazardous or hazardous areas.

Online condition

monitoring

Online condition

monitoring

p Global 2014 59

STERLING SIHIGERMANY

had a break down 2 to 3 times a year

with high repair and maintenance

costs, as well as long downtime of

the plant. On the suction side of the

pump, a filter is installed. Sudden

or gradual clogging of filter leads to

cavitation in the pump. Cavitation

operation produces an unaccepta-

ble exposure to vibration and leads

to insufficient lubrication of sleeve

bearings. Damage to the bearings

are the inevitable result. By install-

ing Sihidetect could be ensured that

the cavitation was detected in an

early stage. Following the assign-

ment of alarms the process control

operation personnel could respond

directly. The pump was switched off

for a short time and the filter was

cleaned, so that a safe and permis-

sible operation of the pump is given

again. At the end the production

downtime was decreased to a mini-

mum and consequential damages of

the pump was avoided.

www.sterlingSIHI.com

missible vibration boundary values,

an email containing additional infor-

mation about the warning or failure

message is automatically sent to the

user (operation manager, distributed

control system, maintenance, etc.).

In the case of a failure message, our

vibration experts will develop a de-

tailed analysis of the trend data,

through which potential process op-

timizations can be introduced.

Process optimisa-tion through online condition monitoring

In a production plant a magnet-

ic driven pump is used. This pump

read and a professional trend data

analysis carried out.

Remote online condition monitoring

For remote online condition

monitoring, the Sihidetect iCMS

(intelligent condition monitoring

system) service agreement has been

developed. In this case the machine

to be monitored is equipped with

Sihidetect and the data transfer

box on site. The measured data are

transferred to the Sihi data server

via the GSM modem and then saved

and analysed by a special software. If

there are any deviations from the per-

the machine being monitored and

provided with a power supply of be-

tween 11 and 30 V DC. This power is

supplied via the existing electrical

connection box that already sup-

ply other installed sensors (tem-

perature, pressure, etc.). If the user

requires only a visual indication for

the machine condition only the Sihi-

detect sensor is required. The condi-

tion of each machine is shown by the

LEDs on the sensor (green, yellow,

red).

Often users like to get the con-

dition information integrated into

the local distributed control system.

Due to the 4 – 20 mA current inter-

face of the sensor the Sihidetect

data can be easily integrated in

existing control or process control

technology. This data can also be

transferred via wireless technology.

If the transferred data is also to be

recorded for subsequent evaluation,

the Sihidata USB trend data memory

is also installed. Using Sihi Vibrosoft

software, the error memory can be

mFor different pump user requirements regarding the

installation specific Sihidetect online solutions have bee developed.

Where Innovation Flows Innovative Engineering.

Superior Quality.Unmatched Productivity.

From pumps serving industrial and polymer markets, to filtration systems delivering pure melt and pelletizing systems that produce perfect polymer products, Maag and Automatik deliver customer-centric system solutions that deliver a competitive advantage, build business and drive revenue.

Let us serve you.

Automatik & Maag. Value built in.

www.psgdover.com www.maag.comAutomatik Plastics Machinery GmbH Ostring 19, 63762 Grossostheim, Germany T: +49 6026 503 0 info@maag.comDover Pump Solutions Group (Europe) GmbH Aspstrasse 12, 8154 Oberglatt, Switzerland T: +41 44 278 8200 welcome@maag.com

Your success in good hands

Tell us what you’d like, and we’ll listen intently. You want to transport fluids; we provide the pumps and valves ideal for your plant. Competitors try to do the same, of course. The difference with KSB? Our employees’ skill in finding an answer for almost every fluid and application. KSB products are just as much at home in municipal utilities and industrial plants as they are in skyscrapers, power stations, mines or oil rigs. www.ourtechnology.yoursuccess.ksb.com

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