landy screw umps & h ydropower screws · landy screw pumps screw pumps and screw pump...
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L A N D Y SC R EW PUM P S& H Y D RO POWE R SCR EWS
For all your UK aftermarket needs and supply of new products
www.ecsengineeringservices.com
L A N D Y SC R EW PUM P S
WIDE APPLICATION POSSIBILITIES
Applications for the screw pump are countless:effluent pumping stations in WWTPintermediate pumping stations in WWTPreturn sludge pumping stationshydropower screwfish-friendly screw pumps for fish passageirrigation projectsdrainage projectsreclamation of wetlandscirculation within aeration systemswild water rides in fun parksindustrial applications storm water applications
INTRODUCTION
Landustrie has a broad experience in the field ofscrew pumps and screw pump installations. Fornearly 100 years Landustrie has designed,manufactured, supplied, erected and maintainedmany types of screw pump configurations. Sincethe early eighties Landustrie has used a fullyautomated screw pump selection program whichenables the engineers to select the optimum screwpump for a particular application. The program isbased on a large number of tests, with an equalnumber of variables, in the Landustrie test facility.The accompanying calculation method has, forseveral of our orders, been approved byGermanische Lloyds. In addition, Landustrie hasdeveloped, over many years, its specific pumpknowledge base, which is continuously updated bymeans of R&D and the latest technology – forexample using Finite Element Analysis (FEA)methods. The latest range of the Landustrie screwpump also covers the hydropower screw pumps. Allthis knowledge and experience makes Landustrieone of the leading manufacturers in the world ofscrew pump installations.
PRINCIPLE OF THE SCREW PUMP
The principle of the screw pump is an inclinedtube, provided with blades, which by rotating liftthe medium to a higher level.
CROSS-SECTION Z-Z
LANDY SCREW PUMPS
Screw pumps and screw pump installations ingeneral are characterized by the following features:
open, clog-free, simple and robust constructionhigh efficiency, low maintenance, lowoperational costshighly reliable, long lifetime and virtually no wear(no spare units required)automatic adjustment of the pump capacity asa function of the incoming flowoperating in a wide range, with a capacity from10 to 11.500 l/s and lift from 0 to 12 mchanges in the capacity are easy and, ifnecessary, steplessinsensitive to supply conditions and also(because of the low rpm) no problems withcavitationcustom-made for each project
Cross-section Z-Z Chute point
Max.pumpingpoint
Touch point
Fillingpoint
D = DiameterJ = No. of flightsN = SpeedS = Pitch
L = Flight lengthH = Nominal liftF = Tension� = Inclination
SCREW PUMP TERMINOLOGY
The picture below shows the most commondefinitions regarding screw pump installations:
FISH-FRIENDLY SCREW PUMPS
The Archimedean screw pump can easily beconverted into a very fish-friendly version:
The diameter of the blades will be increasedgradually from the tube towards the outsidediameter of the screw pumpThe blades will ultimately merge with thecasing of the screw pump, in order to preventfish from becoming trapped between theblades and the casingA thicker rounded edge at the start of theblades to create pressure waves in the waterso fish will be directed into the main water flowin order to prevent contact with the blades
With these provisions the screw pump isextremely suitable to pump up water withoutdamaging fish (unharmed > 98%).
L A N D Y SC R EW PUM P S
HYDROPOWER SCREWS
Hydropower installations generate renewableenergy from flowing water resources. This couldbe from a lake, disused locks at weirs or indownstream flows. The major advantage ofhydropower is the possibility of 24 hour use.Most of the energy generated is fed back into thegrid or alternatively used on site.
Feed-in tariff regulations for renewable energyexist in most countries. Depending on the energysource, tariffs are paid on a per-kWh basis. Thismakes it worthwhile to use renewable energy. Anefficient use of water power is already achievedat a level difference of 1 m and a capacity of 500 l/s. The largest capacity and leveldifference for hydropower screw units is as muchas 15000 l/s at 10 m.
Note: energy generated from flowing waterresources gives the highest efficiency rating of allsustainable energy sources!
Benefits of hydropower screw pumps:
Highest efficiency (up to 86%)Simple installationEasy implementation in existing situations (nocivil construction work)Extremely fish-friendlyInsensitive to cloggingLow maintenance costsLong life timeImprovement of water quality24 hour energy supplyActive flow control without extra lossesPossibility to switch over to pump functionSelf-regulating to changing water flow
Hydropower screw at Windsor, UK
General Rule of Thumb Calculation of electrical power output is:
H(m) x Q(m3/s) x g(9,81m/s2) x 0.75 = P (kW)
Energy production per year:P (kW) x 8760 (hr) = (kWh/y)
lower bearing, the maintenance is limited to an annual oilchange and periodic checking of all greasing points. Allthese factors lead to very low operational costs forLandustrie screw pump installations.
HIGHLY RELIABLE, LONG LIFETIME AND HARDLYANY WEAR (NO SPARE UNITS REQUIRED)
The robust construction of the screw pump body and bothbearings, the use of standard components such as electricmotors and gearboxes at low revolutions gives the screwpump a unique reliability record. With intensive use alifetime of 20 years is normal. Even screw pumps whichhave been in operation for more than 40 years occur quiteregularly. An additional advantage of the extreme reliabilityis that no spare unit needs to be considered at designstage.
AUTOMATIC ADJUSTMENT OF THE PUMP CAPACITYAS A FUNCTION OF THE INCOMING FLOW
The capacity of the screwpump is automaticallyadjusted in the event thatthe incoming flow is lowerthan the screw pumpcapacity. When theincoming flow is greaterthan the pump capacity,the discharge will belimited to the screw pumpcapacity. Because of thisequable flow regime, ascrew pump is extremelysuitable as an effluentpump for a waste watertreatment plant, ashydraulic overloading isprevented.
Incoming flow at filling point
Incoming flow above filling point
Incoming flow below filling point
OPEN, CLOG-FREE, SIMPLE AND ROBUSTCONSTRUCTION
Depending on the medium (in most cases rawwaste water) several kinds of contamination canoccur. The screw pump has an importantadvantage: due to its open construction, screenscan be situated behind the screw pump, if required.
This results in lower civil costsof the total installation.By means of its advancedscrew pump selection program,Landustrie is capable ofselecting screw pumps which,in many cases, will have twoflights. This offers advantagesin respect of less deflectionbecause of the lower tensilestress, lower welding tension,and lower resultant forces on
the civilconstruction.This in turn willallow bigger lifts.As a standard,Landustrie, basedon nearly acentury’sexperience,allows for atensile stress of
20 N/mm2 maximum, and a maximum deflection ofL/2500. The actual stress is determined using FEA.All selected screw pumps can be supplied in eithera coated steel or stainless steel version in AISI304or AISI316. Other exotic materials are alsopossible.
HIGH EFFICIENCY, LOW MAINTENANCE, LOWOPERATIONAL COSTS
Because of contamination of the medium, theefficiency of screw pumps for this application willbe much higher than for other types of pumps.Moreover, the screw pump is ideally suited to copewith variations in the incoming flow whilst workingat a nearly constant efficiency (see under automaticadjustment of pump capacity). Also, the lowernumber of revolutions of screw pumps adds to therelatively high efficiency of the overall installation.Because the complete screw pump installation isbuilt up from an electric motor, gearbox, upper and
L A N D Y SC R EW PUM P S
Screwdiameter
(mm)
Max.speed(r.p.m.)
Capacitymax
(m3/sec.)
30°Ho
max.(mm)
Capacitymax
(m3/sec.)
Homax.(mm)
Capacitymax
(m3/sec.)
Homax.(mm)
35° 38°
300 118 0,016 2800 0,012 3200 0,011 3500450 98 0,041 4000 0,033 4600 0,029 5000600 75 0,082 4700 0,066 5400 0,059 5900800 62 0,154 5500 0,125 6300 0,0112 69001000 53 0,272 6700 0,218 7700 0,196 84001250 46 0,430 7700 0,360 8900 0,312 97001500 40 0,690 8600 0,556 10000 0,500 109001800 36 1,080 9800 0,866 11400 0,777 125002100 32 1,500 9200 1,210 10500 1,087 115002450 29 2,210 8000 1,770 9100 1,591 100002800 26 2,980 10500 2,390 12100 2,150 133003200 24 4,070 10600 3,273 12100 2,940 133003600 22 5,360 11000 4,306 12600 3,860 138004050 21 7,060 11400 5,670 13000 5,090 142004500 19 9,000 11700 7,240 13300 6,500 146005000 18 11,530 12000 9,260 13600 8,320 14900
WIDE DESIGN RANGECAPACITY FROM 10 TO 11,500 L/SLIFT FROM 0 TO 12 M
Every single screw pump is specifically designedand therefore tailor-made for each project. Thisalways gives an optimum balance betweenfunction and design, varying between capacitiesof 10 and 11,500 l/s. As regards the lift, thepossibilities are practically unlimited when screwpumps are installed in series. The adjacenttable shows an indicative overview of the mostcommon options. Also screw pump installationswith different inclinations, which were quite oftenused in the past, can be quoted on request.
Screw pumps in serial order
CHANGES IN CAPACITY ARE EASY ANDSTEPLESS IF NECESSARY
The capacity of the screw pumps is easy toadapt by simply adjusting the speed of thescrew using a multi speed motor or a variablefrequency drive (VFD). To adapt the speed of afixed speed screw, the pulleys of the V-belttransmission can be changed. In all but a fewcases the efficiency will be maintained afterchanging the speed. This characteristic is veryimportant. Most installations do not get the inputfor which they are designed. Therefore it isimportant that the input in practice will bepumped as efficiently as possible. So if theactual input deviates substantially from thedesign input the efficiency of the total installationwill not be reduced in situations where screwpumps are installed.
.
INSENSITIVE TO SUPPLY CONDITIONSAND, BECAUSE OF ITS LOW SPEED, NOPROBLEMS WITH CAVITATION
Because of the low revolutions and the nature ofthe screw pump no special demands have to bemet regarding the inlet channel of the screwpump. The screw pump is, contrary to othertypes, insensitive to supply conditions. Even athigher revolutions when critical supply conditionscould lead to cavitation, which in practice canoften occur with competing pump designs, thescrew pump maintains its efficiency levels.
Filling point
Touch point
Pump efficiency
Pump capacity
Discharge and efficiencyat various inlet levelsbelow filling point
SCREW PUMP SIZING
Many years of research and experience havegiven Landustrie the ability to select the efficientapplication for each screw pump. The optimumcombination of inclination, pitch/diameter ratio,diameter/tube ratio and number of flights willresult in substantial savings of both investmentand operational costs.
The increase in wear resistance also leads toenergy savings: a wear resistant layer betweenthe screw pump and the trough means a fixedclearance for the lifetime of the screw pumpinstallation. Increasing leak losses because ofsand, gravel and other dirt will no longer occur. Aperfect trough is essential in order to build highlyefficient screw pumps.
HIGHER EFFICIENCY
New screw pumps are often installed by using acasting mould for creating the concrete trough.The advantage of this method is that a superiorquality of concrete trough can be achieved.Also, concreting is less dependent on weatherconditions and craftsmanship.
TROUGHS
The choice of troughs presents several options.First of all there is the classic concrete trough, forwhich the screw pump itself is used to grout thetrough to its final shape, working at low speedand using a special mortar. When this specificknow-how is not available it is possible to ordereither a screw pump with a steel casting mouldwhich is removed after the concrete has beencast, leaving the correct clearance between thescrew pump and the concrete.
This can also be done with a cast-in steel (orstainless steel) trough, which will remain in theconcrete. For special applications there is alsothe option of a fully self-supporting steel troughor a completely pre-fabricated screw pump,including trough bearings and drive-unit. The lastoption has the advantage that installation time isextremely short. For smaller screw pumps, apre-fabricated pump can be installed as a tubescrew pump.
TROUGH TYPE CONCRETE CASTING MOULD STEEL (LINER) PREFABRICATED TUBE TYPE FISH FRIENDLY
Optimal clearanceWear resistantconcrete Short installation Short installation
ADVANTAGE Optimal clearance Smooth surface Easy to install time time Suitable for fish
Cheap Very easy to install Very easy to install passage
Multipurposemould
Installationexperience Slightly less Expensive Limited in
DISADVANTAGE required None efficient Slightly less diameter/Q/H Slightly more
Non-wear resistant Slightly more efficient Less efficient expensive
concrete expensive Expensive
L A N D Y SC R EW PUM P S
LOWER BEARINGS
For the lower bearings Landustrie hasthree different standard types. The mostrecent is the Landy Eco-friendly lowerbearing, with a number of specificadvantages (see the adjacent 3-D image)In the table we have compared the fourdifferent Landustrie lower bearings. Alllower bearings, of any type, only have toabsorb radial forces. The lower bearingalso absorbs the heat expansion andcontraction of the screw.
Completely enclosed unit
No maintenance and no grease costs
3-dimensional self-aligning
Corrosion-freecast iron housing
Lower investment
No spare parts required
Exchangeable withexisting bearings
No grease pump andgrease lines required
Easier to install
Eco-friendly lubricated for lifetime of the bearing
High-performance seal
Eco-friendly Conventional Heavy Duty
Lubrication Lifetime Grease Grease
Grease filling l l
Grease return line NA On request l
Maintenance required l
3D-self-aligning l l
Installation time low average average
Heavy duty l
Exchangeability with existing bearings l l
Investment low medium high
Operational costs low medium medium
Lifetime average average long
LOWER BEARING SELECTION TABLE
ECO-FRIENDLY LOWER BEARING
Wall-mountedbearing
WATER-IN-OIL DETECTION
All Landy Eco bearings can be fittedwith a water-in-oil alarm system. Thissystem gives an alarm when a certainamount of water or some otherconducting medium has polluted the oilin the bearing housing. The system canbe fitted to new bearings as well as beretrofitted to existing bearings.
UPPER BEARINGS
For the upper bearing Landustrie can offer thechoice between two different versions; awall-mounted or a foot-mounted upperbearing. The preference is normally forthe wall-mounted upper bearing, firstlybecause the forces on the civilconstruction will be better absorbed, andsecondly because an odour-tightseparation is created between the screwpump and the room in which the drive-unitis installed. Foot-mounted bearing
L A N D Y SC R EW PUM P S
DRIVE-UNIT OPTIONS
Depending on the local circumstances there is achoice of different drive-unit arrangements.Different options are shown schematically in thedrawing below. Deviations from these guidelines is,of course, possible, if so required.
TOTAL COST OF OWNERSHIP
Any screw pump installation will perform betterthan any other type of pump based on Total Costof Ownership. This is due to better efficiency over alarge working range of the screw pump, lessmaintenance and a superior life time of theinstallation.
AFTER SALES
ECS’s after sales service is the customersconnection to Landustrie not only for the supply ofspare parts but also for training and supervision. Inaddition, installation upgrades, some of which haveamazingly short payback times through savings inenergy and maintenance, can be carried out onexisting applications.
01773 860001
RENOVATION OF EXISTINGINSTALLATIONS
ECS is capable of renovating any screw pumpinstallation including those supplied by othermanufacturers. Due to our vast experience we willguarantee that installations renovated by ECS willbe improved by at least 15% in terms ofoperational cost.
RESEARCH AND DEVELOPMENT
For many years Landustrie has been active inresearch to improve the screw pump even further.The most recent results are the Eco-friendly lowerbearing, which has been tested for over 10 years.In addition, the latest developments withhydropower screws have been tested in-house ona 1:1 scale, as well as the increased use of theFinite Element Analysis techniques on theLandustrie screw pump designs.
Direct drive
V-belt transmission
ECS maintenance engineers
LANDY SCREW PUMPS BECAUSE...
Besides the general characteristics of the screwpump, the Landy screw pumps are distinguished by:
In other words a first class product with
screw pump technology
Minimum tolerance on outside diameter Efficient design -
- Usually 2 flights- Limited deflection- Limited occurring tension- High efficiency
Ongoing R&D
Finite Element Analysis
Full in-house manufacturing
Totally reliable manufacturing schedulesand delivery times
Endplates- Fully watertight by means of caps
over threads of connection bolts- Fully parallel and concentric manufacture
using special lathesReinforced leading edges of flights
Manufactured with permanent lifting eyesand balancing weights
Fully qualified welders- X-ray or ultrasonic- Welding ShopApproval
Alignment of the screw
pump by machining the
bearing joint face
Coating. All required coatings areapplied professionally, and can besupplied with additional requirementsregarding sand, salt or pH.
Basic material of bearing shafts is nodularcast iron
Use of fully self-aligning bearings
Nearly 100 years experience
World-wide service with local support
Superb after-sales service
Erection with competent and experienced Landustrie mechanics. On request, we can also offer fullsupervision of installation
STATE-OF-THE-ARTSTATE-OF-THE-ART
L A N D Y SC R EW PUM P S
10-2
013
1000
UK
ECS
REFERENCES
During the nearly 100 years of their existenceLandustrie has undertaken some 7,000 screwpump projects, which are all unique in terms ofdesign and execution, varying in power from 1 to600 kW and in diameter from 10 cm to 5 meter,and in length from 50 cm to 25 m. All theseprojects have added to the vast amount ofknowledge and background information built upover the years regarding the design,manufacturing and installation of screw pumps. For every new project, you, as our customer, areusing this inexhaustible amount of experience.You will find some of our most recent projects inthe adjacent photo collage.
COVERS
On request Landustrie can cover the installationwith a modular light weight synthetic coverconstruction. Advantages are:
protection of the screw pump against thermalexpansioncreates a safe working environmentreduces the level of noise production
ECS ENGINEERING SERVICES:INSTALLATION
ECS has a great deal of experience in this fieldand is supported through its supply distributionagreement with Landustrie and is capable ofdelivering any size of project. ECS offers acomplete service from the initial site visit,through design, installation and commissioning.Design engineers will produce bespokespecifications for each individual applicationwhich will be installed by qualified andexperienced personnel to the highest standards.
REPAIR & SERVICE
ECS also offers a complete package ofmaintenance and repair services for allArchimedes type screw pumps including round-the-clock emergency breakdown cover. Forcustomers looking to maintain and improve theefficiency of existing installations, ECS has theexperience and the expertise to deliver a reliableand efficient solution for every applicationincluding hydro-power screws.ECS has a large number of field basedinstallation & service engineers with fullyequipped vehicles that can remove and repair alltypes of screw pumps.
Veneriete, The Netherlands (renovation)
Windsor, UK
Windsor, UK
ECS Engineering ServicesBrookhill RoadBrookhill Industrial EstatePinxtonNottinghamshireNG16 6NS Telephone 01773 860001Facsimile 01773 810003Email [email protected]