advantages with nessie high pressure water pumps pah … · strength and weakness nessie pumps...

• Axial piston pump:• Based upon well know principle from oil

hydraulics.

• Swash plate type with fixed displacement.

• Various displacements in same building frame.

• High efficiency• Compact design• 50 - 100 cc/rev• 68 – 145 litre/min output flow• 160 Bar Continues pressure• AISI 304 Stainless Steel Housing

Advantages WithNessie High Pressure Water Pumps PAH 50-100

• Service intervals:-No maintenance required in the field.-Every 8000 hours.-Recommended to operate pump every 3 months.

• High efficiency:-Total efficiency > 90 %.

• Low weight:-PAH 80 stainless = 0.97 kg / kW.

• Very Compact:-PAH 80 Stainless = 0,2 litre / kW.

Strength and WeaknessNessie Pumps compared to Plunger pumpsNessie Pumps Plunger Pumps (CAT, Speck)

• Service intervals:-Oil change after 50hours-Hereafter every 3 months or 500hours.-Recommended to operate pump every 3 months.

• Good efficiency-Total efficiency =85-90%.

• Heavy:2.5-5.5 kg / kW.

• Large:-1,0-3,5 litre / kW.

• Mounting:-Any direction-Alignment at shaft is important.-No axial load to the shaft is important.

• Inlet conditions:-Pressure range 0,9-5,0 bar abs (0-4bar)-Sensitive to pressure spikes >7 bar.-Self suction (no boosting required).-Cavitation reduces service intervals.-Do not run the pump dry.-Water temperature < 60°C. (up 75°C)

• Mounting:-Horizontal only.-Uneven surface may damage pump case.

• Inlet conditions:- Pressure range 2,3-5,8 bar abs (1,4-4,9bar)-Inlet pressure <2,3 bar = reduced efficiency.-Do not starve or run the pump dry.-Water temperature < 55°C



• High shaft speed (1800 rpm)-Direct connection to el-motor or combustion engine.

• Very low pressure-ripples (< 2 %)-Reduced risk for water hammer.

• Storing:-Drain for water and flush with glycol to prevent frost damage and pitting corrosion.

• Low shaft speed (<1200 rpm)-Need to be belt/gearbox driven.-Need 6 pol motor for direct connection.

• High pressure-ripples (Approx. 15 %)-Need pulsation damper.

• Storing:-Drain water and flush with glycol to prevent frost damage and pitting corrosion.


• Filtration:-10µ abs is recommended (8000 hours service interval).-Reduced filtration reduces the service interval.

• Few components:-Reduced risk for failures.-Easy to service (if needed)-11 dynamic parts/2 bearings-0 dynamic sealing/only static sealing

• Filtration:-50µ is recommended.-Reduced filtration reduces service interval.

• Many components:-Larger risk for failure.-More complex to service.-13 dynamic parts/8 bearings-6 to 18 dynamic seals


• Run pump every 3 months for 5-10 minutes.

• 8000 hours operation between service.

• Inspect the pump every 10 years.

Danfoss Solutions For Reverse Osmosis For decades water has been a focal point of our business, and our contribution to water systems worldwide covers

a broad range of products. Among them are:

Products Danfoss A/S RO Solutions is part of the global Danfoss A/S group producing components and high-pressure pump systems

for the RO market.

Pumps With our APP pumps especially developed for purification applications, we can provide a cost-effective pump for e.g.:

• Reverse Osmosis

• Nanofiltration

• Ultrafiltration

• Microfiltration

• Other low viscosity (>2ct) fluids prefiltered down to 10 micron absolute

Well-proven Technology

The APP pumps (Axial Piston Pumps) are based on the axial piston principle. This principle was developed in the 1950s for oil

hydraulic applications and revised further in the 1980s by Danfoss for water applications.

With thousands of pumps running in a variety of applications, the design has long since proved to be among the most reliable

and cost effective in the market.

1. Shaft sealing

2. Mounting flange

3. Bleeding plugs

4. Retaining ring

5. Piston/shoe

6. Valve/thrust plate

7. Swash plate

8. Cylinder barrel

9. Spring

10. Port plate

11. Connecting flange

12. Housing with bearing

Technical data APP 0.6-1.0 specifications:

Metric measure US measure

Flow APP 0.6 10 L/min 2.6 GPM

APP 1.0 17 L/min 4.5 GPM

Discharge presure 10 to 80 bar 140-1150 psi

Inlet presure Flodded to 7 bar Flodded to 100 psi

Pump rpm 700-3000 rpm 700-3000 rpm

Horse power at 80 bar APP 0.6 1.5 kW 2 HP

APP 1.0 2.2 kW 3.2 HP

Weight 4.4 kg 9.7 lbs

Inlet port ½" BSP ½" BSP

Outlet port ½" BSP ½" BSP

Common material specifications:

All wetted parts: superduplex, polymer, ceramic

All external parts: Superduplex, 316 SS, plastic

All pumps shown are available in AISI 304 stainless steel

APP 1.8-2.2 specifications:



APP 2.2 35 L/min 9.2 GPM



Pump rpm 700-3000 rpm 700-3000 rpm

Horse power at 80 bar APP 1.8 4.2 kW 5.7 HP

APP 2.2 5.5 kW 7.0 HP

Weight 7.7 kg 17 lbs

Inlet port ¾" BSP ½" BSP

Outlet port ½" BSP ¾" BSP





APP 6.5-10.2 specifications:



APP 6.5 108 L/min 28.1 GPM

APP 7.2 120 L/min 31.2 GPM

APP 8.2 136 L/min 35.4 GPM

APP 10.2 170 L/min 44.2 GPM



Pump rpm 700-1800 rpm 700-1800 rpm

Horse power at 80 bar APP 5.1 12 kW 16 HP

APP 6.5 15 kW 20 HP

APP 7.2 17 kW 23 HP

APP 8.2 19 kW 25.5 HP

APP 10.2 24 kW 32 HP

Weight 32 kg 70 lbs

Inlet port 1) 1½" BSP 1½" BSP

Outlet port 1) 1¼" BSP 1¼" BSP





Valves Our goal is to offer valves in seawater resistant

materials to be used with the APP pumps and pump

systems.

The VCM valves are mainly used to prevent the pumps

from spinning backwards - which, however, is not

harmful to the pumps, but the low-pressure feed line w

be protected against high pressure in case of sudd

power cuts.

ill

en

Pump Systems Although the biggest APP pump 뱋nly? supplies

10,2 m3/h, it is possible to increase the feed flow to the membrane.

Danfoss A/S RO Solutions can provide a variety of pump systems on

frames in all sizes ?up to

40 m3/h feed flow ? and we are still competitive on price.

Special pump systems for hazardous areas are supplied regularly for

offshore applications with all the necessary approvals.

Benefits • Low Energy Consumption

• Long Service Life

• Corrosion Resistance

• High-Pressure Operation

• Wide Flow Range

• Constant Flow

• Low Pulsation

• Compact design

Low Energy Consumption Total efficiencies up to 95 percent – among the most efficient in the market.

"Click on picture to enlarge"

http://www.nessie.danfoss.com/images/kurve1.jpg

Long Service Life Danfoss guarantees service free operation for more than 8000 hours.

Pumps correctly operated often run 25,000 to 30,000 hours without

service.

New Design ensuring long Service Life

• Pump self-lubricated by the water itself. No need for oil lubrication.

• Few wearing parts. The design does not require valves inside the

pump.

• Corrosion resistant materials.

Corrosion Resistance All wetted parts of the pump are designed in duplex, super duplex

stainless steel and polymer, ensuring resistance to corrosive and

low viscosity fluids, e.g. seawater and brackish water.

Material specification:

W.Nr. EN SS UNS

Stainless steel: - 1.4410 2328 S32750

Stainless steel: 1.4462 1.4462 2377 S31803/S32205

Ceramic, Carbon and NBR rubber.

Carbon reinforced PEEK.


High-Pressure Operation Continuous operation at a discharge pressure between

10 and 80 bar (145-1160 psi).

Higher discharge pressures are available on request.

Wide Flow Range One pump size covers the same flow range as several centrifugal pumps, because the flow is a linear function of

the speed (rpm).

The pumps run at speeds between 700 and 1500 rpm (APP 10.2), 1800 rpm (APP 5.1 to 8.2),

3000 rpm (APP 0.6 to 2.2).


http://nessie.danfoss.com/images/kurve2.jpg


Constant Flow Unlike other pump principles, the APP pump provides an almost constant flow regardless of variations in the

pressure.

This means that the flow will remain constant irrespective of e.g. a gradual membrane contamination.

Low Pulsation A design featuring up to nine pistons reduces pressure pulsations in the discharge line down to 1.5 percent,

making pulsation dampers unnecessary, and reduceing installing cost.


Compact Design The most compact pump on the market, giving system

builders a free hand to design more compact systems.

The pump may also be directly mounted onto an

electrical motor via a bell housing with a flexible.

Typical pump unit (electric motor 18 kW/24 HP,

bell housing and APP 8.2 pump):


Pump A mm (in) B mm (in) C mm (in)

APP 0.6

and APP

1.0

130 (5.12) 114 (4.49) Ø 88 (3.46)

APP 1.8

and APP

2.2

162 (6.38) 114 (4.49) Ø 105

(4.13)

APP 5.1 to

APP 10.2 248 (9.76) 208 (8.19)

Ø 168

(6.61)

http://www.nessie.danfoss.com/images/180-537_big.gif

References

Sea water with energy recovery

Application: New water maker for hotel

Place of installation: Spain - Mainland

Brackish Water

Application: Brackish water

3 APP 2,2 equiped with inverters for flexible use at universety

Place of installation: UK

Sea Water with Energy Recovery

Application: Municipal water makers

4 parallel pumps together with energy recovery.

Place of installation: Peru


Application: Water maker

2 x APP 8.2 as high-pressure feed pump together with energy recovery

Place of installation: Lanzarote

Sea Water


APP8.2 pump set as high-pressure feed pump

Place of installation: Greece

Sea Water

Application: Off-shore water makers

Ex-proof APP10.2 pump sets with stainless steel bell housings and ex-proof motors for

offshore oil rigs

Place of operation: North Sea

http://nessie.danfoss.com/Images/applications/ro02.jpg

http://nessie.danfoss.com/Images/applications/Ro17.jpg


http://nessie.danfoss.com/Images/applications/ro01.JPG



Reversing Pumps for Energy Recovery

Application: Energy recovery by reversing pump

Using a spitted gearbox, one APP 1.0 as high-pressure feed pump and one APP0.6 running

as a sea water motor in the reject line gaining 75% of the energy back and providing a fixed

recovery of 40%



APP8.2 pump set as high-pressure feed pump together with PX-Energy recovery

Place of installatn: Lanzarote

Sea and Brackish Water

Application: Water maker for UN.

2 x APP8.2 inverter driven pumpset.

Place of installation: Global


Application: Water maker for Marina.

4xAPP6.5 inverter driven pump set at less than 2.2 kW/m3.

Place of installation: Turkey



3 x APP 8.2 running in parallel with energy recovery at Hotel.

Place of installation: Spain - Main land


Application: Containerized water maker

Using APP8.2 as high-pressure feed pump. 6 m3/h at less than 2.7 kW/m3

Place of installation: Lanzarote

Water maker

Application: New water maker

Place of installation: Bay of Bengal








Sea Water

Application: Refurbishment of oil rig water maker.

Replacing plunger pump with an APP8.2 pump set

Place of installation: North Sea

Highly Brackish

Application: Containerized RO-skid

3 m3/h inland pilot plant for highly brackish water.

Place of installation: Middle East



16 World Water and Environmental Engineering May/June 2004

PUMPS & VALVES

Advances in seawater RO pump efficiency

For the past year Danfoss A/Shas been evaluating the effi-ciency of its APP high pressure

feed pumps in seawater reverseosmosis (SWRO) applications.

When launching the Danfoss APPpumps, the range only consisted of 6different fixed displacements.

Based on a close cooperation withboth membrane manufacturers andadapting to market needs, the rangehas been increased to comprise 9sizes, and Danfoss is able to supplypump systems tailored up to 80 metres3/h and still maintain thehigh quality standards required of themarket.

High Efficiency - Long LifeWhen in March 2002 the first fieldtest was started, one of the highlightswas the overall efficacy of our APPpumps. Ever increasing energy pricesand the potential for renewableenergy sources forced our develop-ment department to focus on theoverall power consumption of theAPP pumps.

The introduction of new advancedprocesses in not only the designphase but also in our up-to-datemanufacturing facilities has highlycontributed to the final performanceof the Danfoss pump.

To cope with 40°C and 45,000 tdsseawater, the pump material has beenaltered, and the APP pumps are thusmade of Dublex and Superdublexmaterials.

Live SWRO testsOne of the first tests carried out inLanzarote in the Canary Islands on a150 metres3/day unit showed a recordlow power consumption of 2.7kW/metres3. (See Desalination &Water Reuse Quarterly Vol.13/1).

This test was carried out in a con-tainerised unit producing6.2metres3/h fresh water using32,000 TDS seawater at a tempera-ture of 20°C. The APP8.2 pump wasrun by a 15kW electrical inverter-dri-ven motor at around 1350 rpm and60 bar. Overall power consumption

was calculated and measured to be aslow as 2.65kW/metres3.

Containerised units are not onlyused in hotels and marinas, but alsoas the main water supply for remoteislands, on board ships and oil plat-forms.

To address the need to reducepower consumption in such plants, itwas demonstrated in Lanzarote thatthis could be done by running thepumps at their optimum rpm band.This is despite the difference in effi-ciency being only around 2%between a pump speed from 1000 to1800 rpm with typical values of 97%at 1800 rpm.

Meanwhile, a 500 metres3/dayplant in Turkey using energy recov-ery and high specification mem-branes (see Fig. 1) had an overall cal-culated power consumption of 2.04kW/metres3 production based onMediterranean seawater. The pumpsystem consists of 4 APP 6.5 pumpsrunning in parallel, 3 equipped withDanfoss softstarter and the 4. run bya Danfoss VFD to achieve the exactflow of the whole system.

Design driversThe market demand for service andmaintenance-free operation has beenthe largest single issue in the devel-opment phase. Since the APP pumpsare designed in Superduplex andwith tight clearances between thepistons and cylinder bores, sealing isnot required at all.

The internal valve configurationhas been designed not to incorporateany kind of check valves. The final

valve plate design ensures lubricationof the moving parts by the pumpedmedium and at the specified mini-mum speed. Consequently, the mov-ing parts will not get in touch, andthus no wear and tear occurs.

Danfoss guarantees one year ofmaintenance-free operation, and wecan say that no pumps have worn outsince they were put into operationmore than two years ago.

Maintenance-free operation ishighly appreciated not only on shorebut also particularly offshore (i.e. onislands), where there is no real alternative water source available.

Energy recovery Is has been extremely advantageousnot only to work very closely withthe OEMs throughout the designphase, but also to experience howcreativity can take over whenexposed to new technology.

The APP pumps are used by manyOEMs as reversing pumps in thereject stream. This method of recov-ering energy is not new, but what isnew thing is the low-priced and verysimple solution. The setup below(Fig 3) shows two APP pumps with

different displacement ensuring afixed recovery. This is just oneapproach, and at present 6 differentcompanies are ‘playing’ with thesetup that can recover 75-80% of theenergy in the reject stream.

ConclusionLooking back to where we were ayear ago, we conclude that it hasbeen an exciting year for Danfossentering the reverse osmosis market.

Our learning curve has been verysteep, but the close relationshipthroughout the development of theAPP pumps with the OEMs alongwith the participation in exhibitionsand congresses have been a key issuefor our success - only achievablethrough your success.

Fig 3 - Double ShaftedPump/Energy Recovery Setup.

Fig 2 - the offshore containerised RO-skid.

Company: Danfoss A/STel: +45 7488 4235Email: [email protected]

Anders Valbjørn describes the findings and experience from both manufacturers and users/OEMs in the year sinceDanfoss A/S of Denmark introduced its new range of pumps for SWRO applications.

Fig 1 - the pump system for the 500 metres3/day plant in Turkey.

WW6-16 5/17/04 9:20 AM Page 1

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