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| YEARBOOK 2015 | 21st VOLUME
Postvertriebsstück 30878
Entgelt bezahlt
ingenieur verlag nagelUhlandstraße 1D-72631 AichtalGERMANY
PUMPS AND SYSTEMSMADE IN EUROPE
Abel, Germany
Affetti, Italy
Bungartz, Germany
Dickow, Germany
Flotronic, United Kingdom
Flux, Germany
HNP Mikrosysteme, Germany
ITT Bornemann, Germany
Klaus Union, Germany
Knoll, Germany
KSB, Germany
KTR, Germany
Leistritz, Germany
Lewa, Germany
Motive, Italy
ProMinent, Germany
SAER, Italy
Schmalenberger, Germany
Seko, Italy
Schroeder, Germany
Sera, Germany
Uraca, Germany
Wilo, Germany
GlobalATEX zone I inside a twin screw pumpATEX zone I inside
a twin screw pumpITT Bornmann presents this
new feature at Achema – page 18
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PUMPTECHNOLOGY
Delta p – The international MAGAZINE ofGlobalCONTENTS
p Global 2015 – 21ST YEAR
Abel, GermanyElectromechanical diaphragm pump in PVC production plant . . . . . . . . . . . . . . 4
Affetti, ItalyThermoplastic and Fiberglass pumps for corrosive liquids . . . . . . . . . . . . . . . . . 6
Bungartz, GermanySpecial centrifugal pump with high intrinsic safety . . . . . . . . . . . . . . . . . . . . . . 8
Dickow, Germany/Tuthill, USASealless Magnetic Coupled Gear Pumps . . . . . . . . . . . . . . . . . . . . . . . 11
Flotronic, UKNew E Series’ achieves the EHEDG seal of approval . . . . . . . . . . . . . . . . . . . . 12
Flux, GermanyExplosion-proof drum emptying system for materials just capable of flowing . . . . 14
HNPM, GermanyPump for liquid coating materials . . . . . . 17
ITT Bornemann, GermanyATEX zone I inside a twin screw pump . . 18
Klaus Union, Germany“Plug & Pump“ – A New Generation of Double Volute Twin Screw Pumps . . . . 20
Knoll, GermanyIndividual solutions from the progressing cavity pump toolbox . . . . . . . . . . . . . . . . 26
KSB, GermanyNew canned motor pumps for chemical and process engineering applications . . . 28
KTR, GermanyPump coupling optimizing safety and service life . . . . . . . . . . . . . . . . . . . . . . . . 30
p Global 2015
Leistritz, GermanyNew screw pump for API applications . . 36
Lewa, GermanyFrom the rugged process diaphragm pump to the high-precision micro- metering pump . . . . . . . . . . . . . . . . . . . . . 38
Motive, Italy Neo WiFi Inverters . . . . . . . . . . . . . . . . . 40
ProMinent, GermanyNew standards in accuracy and reliability with the new solenoid driven metering pump . . . . . . . . . . . . . . . . . . . . . 41
SAER, Italy The importance of energy saving . . . . . . 44
Schmalenberger, GermanyStepping up the pressure with self-priming centrifugal pumps . . . . . . . . . 46
Seko, Italy More than 40 years in metering and dosing . . . . . . . . . . . . . . . . . . . . . . . . 48
Schroeder Valves, GermanyA valve for high pressures and all load conditions . . . . . . . . . . . . . . . . . . . . . 52
Sera, Germany From baking trays to dosing specialist . . . 53
Uraca, GermanyEfficient marathon runners . . . . . . . . . . . . 54
Wilo, Germany Cost-neutral modernisation secure water supply in Jordan . . . . . . . . . . . . . . . 55
3
p Global 20154
Electromechanical diaphragm pump in a PVC plant
ABELGERMANY
Electromechanical diaphragm pumps
are used for pumping polyvinyl
chloride dispersions. A total of nine
electromechanical diaphragm pumps
as well as two piston diaphragm
pumps are operating in the Europe’s
largest fully integrated polyvinyl
chloride (PVC) production plant is
located in the north of the German
Ruhr region.
The pumps transport flamm able
PVC dispersion with vinyl chloride
content of 5 to 10 % from chemi-
cal reactors into buffer containers.
Originally, the reactor pressure of
ca. 6 to 8 bar was used to transport
the PVC dispersions into the buffer
container. Due to the use of the elec-
tromechanical diaphragm pumps
(EM) whose original pumping pres-
sure is 0.5 bar, the time for emptying
the reactor has been clearly reduced.
This makes it possible to fill the
reactor faster.
Special constructions
The pumps are equipped with
an intelligent diaphragm pulsation
dampeners (iMPD). This special con-
struction has proven to be useful
where minimal residual pulsation
needs to be achieved when pumping
pressures fluctuate. The iMPD auto-
matically adjusts the charge to the
pumping pressure, so that dampening
occurs in a much wider pressure range
with consistently reliable results.
In a different area of the plant,
a piston diaphragm pump of the
CM series (l Fig. 2) has been in
continuous operation for loading a
dryer plant since 2011. This pump is
also made from stainless steel and is
ATEX compatible. The pump trans-
ports hot PVC dispersions of tem-
peratures up to 70 °C and with a
content of solid matter of 40 to 55 %
to a spray dryer. Operating pressures
between 8 and 20 bar are necessary
due to various quality requirements.
Therefore, the pump is equipped
with two conventional diaphragm
pulsation dampeners with different
pre-charge settings.
www.abel.de
Achema: Hall 8.0, H47
mFig. 1 Electromechanical diaphragm pumps in operation.
kFig. 2 Piston diaphragm pump of the CM series
Knows what’s happening... before it even happens.X-tremely clever: the new gamma/ X
METERING
MEASUREMENT & CONTROL
TREATMENT
DISINFECTION
IMPLEMENTATION
Pressure too high or air in the dispensing head? The new gamma/ X automatically detects potential issues – and fi xes them before they can actually turn into problems.
www.prominent.com/gammaX
X Solenoid-driven diaphragm metering pump for 2 to 45 l/h at back-pressure from 25 to 2 bar
X Intelligent control electronicsX Without failure-prone sensorsX Integrated timer for timer-controlled
meteringX Cavitation detectionX Automatic venting system
June 15 – 19 ACHEMA Hall 8.0 Booth J 94
p Global 20156
Thermoplastic and Fiberglass pumps for corrosive liquids
p Global 2015l6
AFFETTIITALY
Thermoplastic and Fiberglass pumps for corrosive liquids
Luca Pacioni
Pumping corrosive liquids pre-
sents many problems, not least in
respect to the material type and
sealing arrangement required.
Affetti Pumps manufactures a full
range of thermoplastic and fiber-
glass (FRP) pumps that are avail-
able in both horizontal and vertical
arrangements and comply with the
required ANSI or ISO standard.
Born in the mid Sixties as man-
ufacturing company of industrial
plants dedicated to containment
and conveying of corrosive liquids,
throughout the last thirty years Affet-
ti Pumps has gained a top speciali-
zation in the realization of pumps
in thermoplastic and FRP material
dedicated to the chemical, sea water,
pharmaceutical, alimentary, gal-
vanic, metallurgy, paper, tanning,
automotive, and water treatment
industries. The company,
based in Castellanza
(VA), preserves total control over
production ensuring for itself pro-
ductive processes upstream and
downstream; design, assembly, fin-
ish, setting up and final testing. In
these last 5 years the company has
obtained good results in terms of
turnover and increased capabilities
and the forecasting is for a signifi-
cant growing, sustained by serious
and important investments.
ANSI/ASME B73.1 pumps
In the last years the company
has presented the line of fiberglass
pumps (Vitrum line l Fig. 1) stand-
ardized ANSI/ASME B73.1 dedicated
to
l desalinization,
l electro-chlorination plants,
l chemical industries and
l aquariums.
The Vitrum line is now the first
product in terms of turnover and
Affetti is forecasting a concrete
growth in the near future for this
product.
The presence of impurities and
sand in sea water makes it neces-
sary to use a material featuring not
only chemical resistance but excel-
lent resistance to abra-
sion. The Series CFG
horizontal centrifugal
coupling pumps are de-
signed according to ANSI/
ASME B73.1, presenting new
features and innovations to be
more competitive and reliable: no-
screwing impeller, separated shaft
sleeve from the impeller, shaft and
base adjustment system are just few
examples. CFM close coupled hori-
zontal centrifugal pumps with ANSI/
ASME B73.1 suction and discharge
out-lets, presents strong and resist-
ant construction.
qFig. 1
p Global 2015 7
AFFETTIITALY
www.affetti.com
Achema: Hall 9.0, B26
of support and documentation and
not least the importance to supply
a product 100 % in accordance with
the client specification.
moplastic solid (PP-PVDF-
PEHD-PVC-PTFE), the seals
are molded in elastomer
(EDPM-FPM-FFKM).
Affetti’s portfolio
also includes magnet-
ic coupling cen-
trifugal pumps
MMB-N/MMB-
E (in self prim-
ing version MSP-
N/E), volumetric
self priming
pumps series VMA
and VGA, enbloc
centrifugal pumps CMO
and CGO with support
and coupling joint, vertical
centrifugal pumps of the series CMV,
CLV, CGV, CGV-N and the recent CGV-S
(cantilever).
The company is able to custom-
ize each product according to the
customers’ needs. The experience
made with the EPC companies in
the last years has permitted to the
company to understand the need
Pump casing are made in Solid
FRP with high thickness to ensure
optimal mechanical strength and
chemical resistance. Fiberglass
pumps can be proposed in alterna-
tive to thermoplastic ones also with
more competitive prices and fast
deliveries.
DIN EN 22858 ISO 2858 pumps
Not only FRP but also thermo-
plastic (PP, PVDF, PE-UHMW, PVC and
PTFE) are available materials. CGD ar-
moured pumps (l Fig. 2), normal-
ized to DIN EN 22858 ISO 2858, are
developd for
l high flow rates and
l heavy-duty tasks.
Proposed with flow rates from
20 to 1,000 m³/h, these pumps with
horizontal axis and mechanical seal
are suitable for installation in pro-
cess plants thanks to the presence of
components with large sections; the
internal parts are made from ther-
Many years of experience coupled with state-of-the-art technologies enable the
to set technological standards!
Many years of experience coupled withstate-of-the-art technologies enable the state-of-the-art
o set technological standardsds!!t
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 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.
HERBORNER PUMPENTECHNIK GmbH & Co KG | Littau 3–5 | 35745 Herborn, GermanyTelephone: +49 (0) 27 72 / 933-0 | Fax: +49 (0) 27 72 / 933-100 | [email protected] | www.herborner-pumpen.de
qFig. 2
p Global 20158
BUNGARTZGERMANY
Typical cases of damage when using centrifugal pumps include the
dry running of the seal and bearing unit. Other malfunctions through
operating error, cavitation, vibrations or difficult pumping media may
cause unplanned stoppages and production loss. In order to prevent such
malfunctions, diagnosis and early detection systems are used. Bungartz
has proven for years that no additional expenditure is required with their
special centrifugal pumps.
of centrifugal pumps are diverse. Of-
ten, the malfunctions are already set
in stone due to the pump selection.
Other than selection and alignment
errors, such damaging vibrations,
operating errors can also be identi-
fied as a cause. For example, these
may be insufficient ventilation,
wrong directional rotation of the
pump, spout drag or closed sealing
systems.
Avoidance of expensive securing and monitoring equipment
In practice, there are various
approaches for minimising the risk
of centrifugal pumps failing. These
include a redundant design and suf-
ficient stockpiling of spare parts. In
addition, companies invest in com-
prehensive operating manuals and
ongoing personnel training. Recent
times have seen an increase in meas-
uring and control technology with
(remote) monitoring, protecting and
controlling components. Measuring
points are installed, gas sensors or
dry-running protection signals are
used and additional components
such as filters, check valves or vortex
breakes are installed. However, this
does not take into consideration that
the additional protection, intended
for reducing the failure rate, can
itself easily contribute to malfunc-
tions and failures. Experts estimate
this to be the cause of up to 50 %
of the problems. At the same time,
an increased expenditure has to be
taken into consideration during the
planning process: Depending on the
size, up to 10,000 Euros per signal
have to be taken into account for the
calculation. (costs for procurement,
integration, repair, maintenance and
documentation, etc.)
Safe, even under difficult conditions
Solid, gaseous and corrosive
media is processed under difficult
conditions in the petrochemical and
chemical industry. The given provi-
sions and legal regulations (e. g.
Germany’s Technical Instructions on
Air Quality Control (TA Luft)) have to
be complied with. The pump manu-
facturer Bungartz is a specialist in
these areas. These robust centrifugal
pumps with high intrinsic safety are
used for pumping extreme media
such as hot sulphuric acid, fertiliser
solid mixtures, mineral oil concen-
trates or materials such as titanium
tetrachloride and ammonium ni-
trate. “The term ‘intrinsic safety’
originates from the field of electri-
cal equipment,” explains Dipl.-Ing.
Sadko Meusel, Sales Engineer at
Bungartz. (l Fig. 1) Even the de-
sign has to ensure that no hazard-
ous situations can arise even in the
case of operating errors. Applied
to pumps, the design again serves
as prerequisite for making external
monitoring systems obsolete. During
his technical presentations, Meusel
explains the use of the special cen-
Special centrifugal
A wrongly designed pump, a
performance outside of the working
point, which can also lead to cavita-
tion formation – causes for failures
m
Fig. 1 Sadko Meusel
Special centrifugal
p Global 2015 9
BUNGARTZGERMANY
for the proven horizontal pumps. Ba-
sically, this seal consists of distinc-
tive vanes on the impeller rear side.
Thus, the pumping medium is car-
ried away from the shaft gap transi-
tion protecting the downstream shaft
seal system. The physical conditions
guarantee a sealed pump, which is
completely independent from the
downstream sealing (mechanical
seal, magnetic seal, lip seal, etc.).
The chemical pump MPCH-
DryRun (l Fig. 2) is also known
for its high availability. In the case
of this hermetically sealed magnet-
coupled pump, bearing and mag-
netic drive do not come into contact
with the pumping medium. This
allows a liquid-independent utilisa-
tion. The labyrinth zone between
the impeller rear side and the shaft
bearing is free of product and filled
with sealing gas, ensuring a ther-
mal barrier with a high temperature
trifugal pumps and reports on the
experiences which plant managers
and pump experts have with the in-
trinsically safe pumps. “Install and
forget,” was a comment made by
an experienced professional. One of
many statements, which times and
times again surprise seminar partici-
pants, due to the long maintenance
intervals and long service lives of the
special pumps.
Increasing availa-bility, saving control technology, reducing costs
Since the company was found-
ed, intrinsic safety of the Bungartz
pumps has always been based on
the intelligent application of physi-
cal principles. One of those is the hy-
drodynamic shaft seal originally de-
veloped by Bungartz, which is iconic
pump with high p
Fig. 2 The chemical pump MPCHDryRun
intrinsic safety gradient and a low bearing tempera-
ture. The grease-lubricated rolling
bearings with a minimum service
life of 32,000 hours do not require
any monitoring or maintenance over
this period. Further advantages are
that the system is ATEX-compliant,
suitable for melting, safe against
blockages and operating error (e. g.
insufficient ventilation). The other-
wise normal signals and controlled
systems are omitted.
One unique property is the self-
regulating behaviour, which is de-
fined as special physics. The centrif-
ugal pumps from the V-AN (AN stands
for abnormal) series (l Fig. 3) work
without suction capacity. They au-
tomatically adapt to changing feed
rates. Here is the principle in simpli-
fied terms: When a medium flows
into a vessel, the liquid level rises
until the inflow and outflow of the
vessel balance out — without any
mFig. 3 The self-regulating
V-AN-type centrifugal pump
pump with high
intrinsic safety
phase (no pits, scaffold-
ing, buffer tanks).
The contact-
free hydrodynamic
shaft seal with seal
expeller and the
idle state sealing
controlled by cen-
trifugal force make
the large circulation
pumps (1,200 m3/h)
of the type M-UMOR
(l Fig. 4) intrinsi-
cally safe in their
entirety. These
pumps (one pump
has been running since 1948!) are
particularly suitable for solids and
are utilised worldwide, e. g. for
pumping ammonium nitrate.
www.bungartz.de
Achema: Hall 8.0, C1
type of mechanical or electrical regu-
lation equipment. All pumps are self-
ventilating as well as safe to run dry
and reliable. They do not require any
kind of controlling (see p Info-Plus)
The self-regulating pumps are
often used for emptying tankers.
They ensure a complete emptying
without applying additional pres-
sure. When emptying from the top,
this can even be used for heavy me-
dia up to a density of 2.4 kg/dm³.
The V-AN series is also in demand
for usage with gaseous or boiling
media. They are ideal for separa-
tion processes with fluctuating feed
rates, because the pumps indepen-
dently adapt to changing volume
flows. The otherwise normal addi-
tional equipment, such as Min/Max
switching system, rotation speed
control through frequency converter
or volume flow measurement, can
be foregone completely. Significant
investment costs can be saved, if
the pumps were taken into consid-
eration early enough in the planning
This animation demonstrates
the principle of self-ventilating
pumps.
p Info-Plus
BUNGARTZGERMANY
lFig. 4 The large circulation pumps of the type M-UMOR
p Global 2015 11
plant and personnel safety, especial-
ly when handling toxic, explosive or
other dangerous liquids which react
on contact with the atmosphere. For
all these services the containment
shell replaces the single or double
acting mechanical seals with exter-
nal fluid reservoirs and the neces-
sary control equipment.
GML/GMB-pumps therefore of-
fer benefits to the chemical, petro-
chemical and allied industries, and
protect the environment. The pump
handles everything from bulk trans-
fer, chocolate and asphalt, to high-
temperature fluids and chemical
processing. The pump is approved
for hazardous areas (ATEX) and suit-
able for liquids which are dangerous
for the environment.
Robust pump design together
with tough and strong materials
make the pump last longer. The ro-
tor and idler gears are made of tough
materials, which can handle the
stresses of high viscosity operation.
No need for steel rotor upgrade. Pat-
ented lubrication method extends
overall life by reducing friction.
The single elements of the
multipolar magnetic coupling are
manufactured of permanent magnet
material “Cobalt Samarium” with
unlimited lifetime. The magnets in
the driven rotor are completely en-
capsulated, not in contact with liq-
uid. Power is transmitted to the her-
metically sealed liquid end by a bank
of external magnets. Inner and outer
magnet rings are locked together by
magnetic forces and work as a syn-
chronous coupling. The containment
shell is a one piece deepdraw design
without additional welds.
www.dickow.de
Achema: Hall 8.0, D54
Sealless Magnetic Coupled Gear
PumpsThe new GML/GMB gear pump com-
bines
l the Dickow magnet coupling
design
l with Tuthill gear pump
engineering
Dickow has more than 30 years
and Tuthill more than 80 years of ex-
perience—the result is a new pump
that offers high performance and
reliability.
Magnetic driven GML/GMB-
pumps are designed to improve
mThe gear pump type GML
DICKOW, TUTHILLGERMANY, USA
p See us in Frankfurt Hall 8.0, Booth L94
p Global 201512
New E Series’ achieves the EHEDG seal of approval
our customers are increasingly
seeking conformance with the high
standards required,” says Flotron-
ic’s Managing Director, Jane Waite.
“Being authorised to display the
EHEDG logo confirms the new ‘E’
series pump’s credibility and gives
our customers peace of mind.”
www.flotronicpumps.co.uk
Achema: Hall 9.0, C82
suction pressure challenges result-
ing from SIP systems, bulk tanks
with head pressure of more than
0.5 Bar, re-circulation and thermal
expansion can all be met by the ‘E’
Series.”
Flotronic designed the ‘E’ Se-
ries for markets at home and abroad
where independent hygiene ac-
creditation is growing in importance.
“While EHEDG accreditation is not
necessarily a statutory requirement,
an electro-polished overall finish.
Cleanability is also assisted by the
incorporation of a support stand
whereby the pump can be inverted
for full draining.
“The ‘E’ series pump passed
EHEDG’s tests with flying colours,”
says Flotronic’s Chief Engineer,
Peter Wheal, “confirming that the
pump meets EHEDG standards for
sanitary product transfer. Other
features, including a diaphragm
rupture detection system with in-
stant pump shut-down alarm facil-
ity and BS, DIN and ISO hygienic
connection options, all help to keep
product contamination free and to
ensure that hygienic standards are
not compromised.”
“A unique feature of the Flo-
tronic ‘E’ Series pump is that the
diaphragms are reinforced as
standard,” Peter continues. “The
reinforcing plates add support to
the diaphragms and ensure that the
pumps can withstand CIP pressures
in the suction line of up to 5 Bar
with no diaphragm damage. Other
Flotronic Pumps Limited, the UK-
based specialist manufacturer of
air-operated double diaphragm
pumps, having already secured 3-A
Sanitary Standards, Inc (3-A SSI)
approval for their recently launched
‘H’ series pump, have now achieved
the European Hygienic Engineering
& Design Group (EHEDG) accredita-
tion for their new E Series pump.
The new E Series pump has
been specifically designed for the
Food and Beverage industry and
other processes where product con-
tamination must be avoided. The
pump’s features include Flotronic’s
established and unique ‘One-Nut’
pump design which allows swift dia-
phragm access without disconnect-
ing process pipework. The internal
surfaces of the E Series pump can
be effectively ‘cleaned in place’ or,
alternatively, easy dismantling can
be carried out for cleaning and in-
spection. Cleaning is aided by the
provision of polished wetted sur-
FLOTRONICUNITED KINGDOM
More information about pump + systems on
l www.delta-p-online.comand the global pump search machine
l www.pumps-directory.com
Our technology. Your success.Pumps Valves Service
ACHEMA – Solutions from a single source for the chemical industry
Get the answers to all of your questions from KSB, the only full-range supplier for pumps, valves and service. We look forward to welcoming you to ACHEMA 2015 from 15 to 19 June. Visit us at stand H14 in hall 8 to benefit from competent and comprehensive consultancy on all services throughout the entire life cycle of your equipment. Learn how we can optimise your life cycle costs, achieve maximum operating reliability and secure the availability of the systems you operate. Find out about our all-in solutions and other fascinating highlights for the chemical industry. Whatever you need. From a single source.
For more information, please visit www.ksb.com/achema
We look forward to seeing you at ACHEMA in Frankfurtfrom 15 to 19 June 2015Hall 8, Stand H14
p Global 201514
World premiere: Explosion-proof drum emptying system for materials just capable of flowing
FLUXGERMANY
The Viscoflux / Viscoflux mobile drum emptying system, espe-cially for pumping highly viscous, paste-like and non-free-flow-
ing materials from the widest variety of drums, has been part of the Flux-Geräte company’s offering for years. Following 2013’s presen-tation of the “Viscoflux lite” system variant, a version for materials just capable of flowing, Flux is now presenting the explosion-proof, PTB approved “Viscoflux lite Ex” version (l Fig. 1) in a world pre-mier at Achema. With this version, after only a year of development work, the supplier is meeting the demands of many operators for an explosion-proof version for emptying drums
l of the widest variety of flammable materials – namely zone 0/1,
l likewise for non-flammable materials which must be pumped in zone 1.
interested parties, such as those from
the paint and varnish industry, are in-
terested in our modular system. How-
ever, they often face the challenge of
needing to use it in zone 1 and/or to
pump flammable materials out of the
drum, namely from zone 0/1. This
gave us the impetus to develop the
explosion-proof version of the Visco-
flux lite, which is now available.”
This explosion-proof drum emp-
tying system is designed like the
non-explosion-proof version and,
after earthing the individual l
“The response to the launch of our
Viscoflux lite device version was ex-
traordinarily positive. The system,
which was developed to remove ma-
terials just capable of flowing from
ISO drums with lids,” says Dr. Jörg
Dassow, Sales Manager at Flux, “op-
erates with an eccentric worm-drive
pump. A vacuum is created in the
drum, so that the follower plate of the
system moves down and wipes the
drum wall. This makes it possible to
achieve complete emptying, down to
less than 1% residual volume. Many
mFig. 1 Viscoflux lite Ex consists of few components – all designed
for explosion-proof use. It is quickly installed and easily transported. It can be used in zone 1 and also pumps the widest variety of flammable materials just capable of flowing from zone 0/1.
World premiere: Explosion-proof drum emptying system for materials just capable of flowing
Discover the Sulzer Partnership
Visit us at ACHEMA in Frankfurt, hall 8 booth A71 and at Power-Gen Europe in Amsterdam, booth 1L47.
Sulzer provides complete pumping sys-tems and service solutions with leading-edge technologies backed by our long-standing expertise in engineering and innovation.
Dedicated teams of experts work closely with you to develop the right solu-
Our customized and innovative ser-
to reduce maintenance time and cost, and
pumps and compressors.Contact us to discover your ideal
pumping and service solution.
www.sulzer.com
p Global 201516
FLUXGERMANY
supply it upon request,” says Büh-
nert. Müller provides an important
note on the topic of potential equali-
sation: “All components must be
earthed outside of an explosion zone
before being joined together. The
operator always specifies the zone
areas.”
Wide variety of applications in zones 0 and 1
Flux thus provides a drum emp-
tying system which can be used in
zone 1. For example, highly viscous
materials just capable of flowing can
be pumped out of the drum directly
in zone 1 of a production system.
At the same time, a wide variety
of flammable materials just capable
of flowing can also be pumped with
this system. Drums with resins, sof-
tening agents or other flammable
materials—the drum interior is zone
0—can be emptied with it easily.
“Our new explosion-proof sys-
tem can be used in the widest variety
of industrial areas,” says Bühnert.
“For example, it can also be used in
production areas in the chemicals
and pharmaceuticals industry in
which solvent vapours make explo-
sion proof necessary. Wherever there
is a zone 1, the explosion-proof
version of Viscoflux lite can now be
used. For example, it now allows us
to provide a solution which enables
pumping lubricants out of the drum
into a plant, directly in this zone.”
www.flux-pumpen.de
Achema: Hall 8.0, E10
have additionally produced
the opening in the follower
plate for the pump tube from
a conductive polyethylene.
This safely prevents impact
sparks from occurring in any
case when inserting the pipe
and in case of contact with
the follower plate.”
The pump centring
plate in the explosion-proof
system is likewise made
from conductive, black poly-
ethylene and has a connec-
tion for earthing wire. In ad-
dition, the handles, arrestor
hook and other attachment
parts also produced from
stainless steel here. The
hose for the compressed air supply,
which serves to loosen the follower
plate from the drum floor, is likewise
implemented in a conductive mate-
rial. The explosion-proof eccentric
worm-drive pump used in the system
has a pipe diameter of 50 mm.
Flux uses proven explosion-
proof motors to drive the new ex-
plosion-proof system. All additional
components of the drum emptying
system which follow on the pressure
side of the pump and which must be
electrically conductive, such as hos-
es and flow meters, are available in
the Flux portfolio in explosion-proof
versions and can be used for the new
system.
“Many operators have their
own potential equalisation or
earthing systems in their plants.
For that reason, we offer Viscoflux
lite in the explosion-proof version
without earthing cable, but of course
highest priority. We assume that
there will be companies in which
the explosion-proof as well as the
non-explosion-proof system will be
operated. For that reason, our design
measures have ensured that the fol-
lower plate and process seal cannot
be combined between the explosion-
proof and non-explosion-proof ver-
sion, for example. In addition, the
explosion-proof follower plate has
stainless steel grips and, of course, a
connection for earthing wire.”
Gerd Müller, Viscoflux develop-
er, adds: “The process seal currently
consists of static dissipative FKM. We
are working on additional conductive
elastomer versions in order to make
the follower plate seal compatible
with as many rising media as possi-
ble. In order to consistently conform
to explosion proof requirements, we
components, can be installed and
operated in just a few steps:
1 Open the drum,
2 put the stainless steel follower
plate with process seal onto the
medium,
3 place the pump centring beam
onto the drum edge and lock it,
4 insert the pump into the
centring,
5 install the hose pipe,
6 put the motor on and connect it,
7 start the motor to begin
emptying.
Focus on operator safety
Helga Bühnert, Flux product
manager, points out a very important
aspect of the explosion-proof ver-
sion: “Safety of the operator is Flux’s
mFig. 2 Drums without inliner are emptied down to less than 1 % residue.
Pump for liquid coating materials
In coating technology a homogene-
ous distribution of the coating ma-
terial is one of the most important
points. An exact coating is required
for a stable and defined modifica-
tion of physical, electrical or chemi-
cal properties of materials. Varia-
tions occurring due to inadequate
technology can lead to a significant
zles or slot dies. The micro annular
gear pump mzr-6305 fulfils these
sensitive metering and dosing tasks.
The micro annular gear pump
mzr-6305 meets the requirements
for exact dosing of liquids with low
and high viscosities. This pump of-
fers a highly precise volume flow
from 0.024 to 144 ml/min. By the 10
to 11 tooth ratio of the rotor set, the
already extremely low pulsation of
mzr-pumps has been further
reduced many times.
HNPMGERMANY
www.gather-industrie.de
Phone: +49 2058 89381-23
Pump Technology
Dosing Technology
Coupling Technology
Flat-face Coupling For water, solvent, acids, bases and more
• Temperature range from –80 °C to +325 °C
• DN4 to DN65
Visit us at
ACHEMA 2015
Frankfurt, 15.–19.06.2015
Hall 8.0, Stand H41
Mini-Turbine Pumps Dosing Gear PumpsTube-Hose Quick-Disconnect Couplings
lack of quality in production. These
quality problems can be avoided
by the application of high precision
pump technology to deliver the liq-
uid coating material, for example,
for a exact feeding of spraying noz-
The coating technology is just
one of many fields of application in
mechanical and plant engineering
for the new pump.
www.hnp-mikrosysteme.de
Achema: Hall 8.0, J95
News, facts, developments about
pumps + systemswww.delta-p-
online.com
p Global 201518
ATEX zone I inside a twin screw pump
Our manufacturing focusses nowa-
days on the twin-screw pumps.
A superior command of tech-
nology in nearly all areas of appli-
cation has made ITT Bornemann a
worldwide leader in its field. Sales
offices and subsidiaries worldwide
ensure that there is immediate and
professional support throughout all
phases of the production process
ranging from detailed advice ex-
tending to tailor-made engineering
and finally including reliable main-
tenance of the installed pumps and
systems. Efficiency, reliability and a
high level of availability are the most
important features that distinguish
Bornemann pumps and systems.
www.bornemann.com
Achema: Hall 8.0, E63
these special application pumps the
most famous advantages are still ap-
plicable. Best suction capabilities,
transferring fluids of varying viscosi-
ties or flow. Even under extreme con-
ditions this pump can resist and it is
still reliable. Long lifetime and cost
effectiveness over the whole product
life cycle are further features.
ITT Bornemann from Obern-
kirchen, Germany, has a long history
of success. Since the company was
founded in 1853, our goal has been
to respond to markets with products
and solutions that are technologi-
cally outstanding and cost-effective.
From that point on, Bornemann has
been setting the pace. In 1934, for
example, it patented the Twin-Screw
Pump with external bearings. In
the 1960s, the development of the
triple-screw pump and the Progres-
sive Cavity Pump led to more inno-
vative solutions, and in the 1980s,
Bornemann multiphase pumps cre-
ated commercial opportunities that
had been previously unthinkable.
factures of mechanical or electrical
equipment need to produce in ac-
cordance to 94/9/EG ATEX 95 direc-
tives.
Today ITT Bornemann twin screw
pumps are used to handle flamma-
ble fluid across all industries where
mixtures of liquid, gas and oxygen
from the atmosphere can occur. In
the past the pumps were already cer-
tified for installation and operation
in Zone 1 or 2, but a Zone inside of
the pump was excluded. Therefor ad-
ditional measurement and devices
were required to avoid dry running or
provide inertisation inside. For that
reason priming and stripping phases
in loading or offloading applications
were sometimes critical to handle.
The manufacturer now invented
a procedure to manufacture Twin
Screw Pumps which can be installed
in these processes which avoid the
above mentioned restrictions. From
now on it is possible to deliver this
twin-screw pump in any applica-
tion where Zone 1 Category 2 is de-
manded by the customer without any
division between inside or outside of
the pump. As an added value highly
sophisticated process measurement
and control equipment for dry run-
ning protection or nitrogen recip-
rocation is not needed any more.
This is another important advantage
which shows ITT Bornemann innova-
tive steps into the future. Even with
Twin screw pumps are self-priming
positive displacement pumps with
external timing gears and bearings.
Manufactured in over 80 sizes, their
design provides excellent suction
performance and eliminates all met-
al-to-metal contact within the pump.
They can handle virtually any fluid,
regardless of viscosity, homogeneity,
lubricity or abrasiveness e. g.
l seawater,
l bitumen,
l molasses,
l lime,
l acid,
l caustic soda,
l polymer solution or
l hydrocarbons.
Today companies in Europe and
other countries which need to act
according to European legislation
have to consider the ATEX directive.
In accordance with the European
directive 1999/92/EG companies
have to define areas where an explo-
sive atmosphere could occur. Those
plants and sites are for example tank
farms, chemistry plants or other pro-
duction facilities which handle with
potential explosive fluids.
For those companies this direc-
tive regulates how the certain areas
and zones within this site shall be
defined and classified. Regarding
those classified areas companies
have to use certified machinery and
electrical devices. And even manu-
ITT BORNEMANN
GERMANY
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p Global 201520
KLAUS UNIONGERMANY
Hans-Jürgen Schöner
A new “Plug & Pump” Design has
been successfully introduced
by Klaus Union GmbH & Co. KG for
Double Volute Twin Screw Pumps
built in accordance with the re-
quirements of API 676, 3rd Edition.
Founded in 1946, Klaus Union
GmbH & Co. KG is a pump and valve
manufacturer located in Bochum,
Germany. The delivery portfolio in-
cludes Magnetic Driven Centrifugal
Pumps, where the company is a
globally leading supplier, Double
Volute Twin Screw Pumps, Valves
and Fittings for all types of indus-
tries.
Applications
Double Volute Twin Screw
Pumps, which have been introduced
to the industries in the first half of
the last century, gained increased
acceptance during the past 30 years.
Incorperating all the advantages of
positive displacement pumps, they
gained more and more acceptance
as a solution for highly sophisticated
pumping applications. Their capabil-
ity of handling products with chang-
ing viscosities at good efficiencies
and a wide speed range make them
an ideal pump for e. g. tank storage
applications. For applications in the
Chemical & Petrochemical indus-
tries, the pumps can be delivered in
various materials ranging from Cast
Steel, Stainless Steel and Duplex
or Super Duplex Steel, vari-
ous Specials Alloys as Hast-
eloy, Monel or Alloy 20 and
even Titanium. Initially, the pumps
have been designed to handle clean
liquids with a neglectible solids
content. Today, with various highly
wear resistant coating materi-
als available, the
“Plug & Pump“ – A Ne
nFig. 2 Rotor Set of a
Double Volute Twin Screw Pump
of Double Volute Twin p
Fig. 1 Cut-a-way of a Conventional Double Volute
Twin Screw Pump
p Global 2015 21
ment Facility. They make separation and treatment
facilities at the well site and separate flowlines for
oil, gas and water obsolete. With the help of Mul-
tiphase Pumps, matured fields can longer produce
with reduced requirement for artificial lift (e. g. gas
injection) or abandoned wells or well clusters can
be revived. Even gas slugs of 100 % can be toler-
ated for certain period of time if a Liquid Control
System (LCS) is installed. Such a system provides
a minimum flow rate, generally approx. 3.0 % of
pumps can handle considerable amounts of sol-
ids without suffering from excessive wear. Sensi-
tive liquids are handled with low shear and almost
no pulsation. All Klaus Union Double Volute Twin
Screw Pumps are self priming up to 8.5 mWc.
Last but not least, Double Volute Twin Screw
Pumps have entered and conquered a very spe-
cial market segment — Multiphase Pumping. With
their ability to handle high gas fractions (GVF), the
pumps are particularly suited for applications on
either Greenfields or Brownfields. Klaus Union
Multiphase Pumps handle the entire untreated
flow from particular wells or well clusters and
transfer the Multiphase Fluid to a Central Treat-
w Generation
mFig. 3 Exploded View of a Double Volute
Twin Screw Pump in “Plug & Pump” Cartridge Design
the total pump flow, in
order to form a liquid
seal between the pump
rotors and the pump cas-
ing insert (liner). This liquid
seal guarantees uninter-
rupted gas compression even
when the well flow does not supply
any liquid phase. Multiphase Pumps are usually
supplied as complete systems with electric mo-
tors or combustion engines, variable speed drives
(VFD), control equipment, piping, valves and ex-
tensive instrumentation which makes them the
Screw PumpsMade in Switzerland
Lowest operating cost and highest availability withfast and easy maintenance.Heavy duty 24/7 design,up to 800 L/min [200 gpm]and 600 kW drive power.Unique membrane-like technology without con-ventional seal packing, ideal for pumping all kindof waters, other non-lubricating liquids or fluidswith abrasive particles.
high
pistonpressure
pumps
HYDROWATT AG CH-8200 Schaf fhausen / Switzerlandwww.hydrowatt.com
visit us at booth 3A48
Düsseldorf, Germany16-20 June 2015
KLAUS UNIONGERMANY
p Global 201522
chanical seals can be provided. It is
possible to use either component
seals or cartridge seals following the
requirements of API 682. The seal
materials are selected to match the
particular operating parameters.
Seal flushing systems meeting the
requirements of API 682, can be
furnished.
The Plug & Pump Cartridge Design
Double Volute Twin Screw
Pumps find applications in almost
any type of industry. However, due to
their special advantages described
above, many pumps find their du-
ties on oilfields around the world.
Many of those locations are in very
remote areas, e. g. deserts, artic
environments, jungles or offshore
The drive torque is transmitted
from the drive rotor to the idler ro-
tor by means of herringbone timing
gears. These guarantee a noise re-
duced operation as well as an easy
adjustment of the pump rotors after
overhauls. The rotors are carried in
heavy duty spherical roller bearings,
which are designed to exceed the
L10 requirements of 25,000 h. Both,
timing gears and bearings are oil
lubricated. The ample sized bearing
and gear covers with large cooling
fins guarantee sufficient heat dissi-
pation. For heavy duty applications,
forced feed lubrication systems can
be provided.
The pumps are sealed by four
mechanical seals (two seals for each
rotor). Depending on the actual op-
erating conditions, single or double
acting, unbalanced or balanced me-
either side to be conveyed and pres-
surized within the axially moving
cavities of the screw packages. The
flow is discharged through the outlet
port in the pump center. This design
makes the pump for 100 % hydrauli-
cally balanced, hence, thrust bear-
ings are not required. Klaus Union
rotors are made from single piece
bar stock. Different screw geom-
etries are available which offer high
efficiencies along with considerable
power savings for selected applica-
tions. All pump rotors are designed
with an exceptionally short distance
between the bearings and a large
core diameter to minimize the shaft
deflection and hence, to prevent
any contact between the rotors and
pump liner at any design condition of
a particular pump.
top product of all screw pump ap-
plications. Double Volute Twin Screw
Pumps in Multiphase applications
can also considerably contribute to
a cleaner environment. With their
ability to handle liquid/gas mixtures
they can prevent the need of releas-
ing greenhouse gases into the at-
mosphere by venting or flaring.
Design Features
Conventional Double Volute
Twin Screw Pumps consist of a pump
casing, a liner which is either inte-
grated or interchangeable and two
pump rotors. Each pump rotor has
two screw packages with similar
pitch but a different pumping direc-
tion. The well flow enters the pump
through the inlet port and splits to
KLAUS UNIONGERMANY
qFig. 4 Placement of the Cartridge on the Installation Tool
pFig. 5 Cartridge Half Way Installed
Roten s.r.l. - Via Ortica, 6 - 20134 - Milano Tel. +39 02 76110157 r.a. - Fax +39 02 7385445 www.roten.it - [email protected]
MILANO 1945
NOI SOSTENIAMO IL FAI - FONDO AMBIENTE ITALIANO
p Global 201524
rFig. 6 Cartridge Completely Installed
pFig. 7 Cartridge on Installation Tool
KLAUS UNIONGERMANY
The “Plug & Pump” Cartridge
Design is available as a standard for
all types and sizes of Klaus Union’s
Twin Screw Pumps Series.
Conclusion
The new Klaus Union “Plug &
Pump” Cartridge Execution marks a
substantial progress in the develop-
ment of a new generation of Double
Volute Twin Screw Pumps. Especially
for installations in harsh environ-
ments, but not limited to, the user’s
benefit from several advantages:
l Quick and easy disassembly
and re-assembly of a pump
l Very short downtime of the
pump unit
l Less production losses during
overhauls and maintenance
shut-downs
l Easy overhaul of the cartridge
unit in the local workshop
l Considerable savings in over-
haul costs
www.klaus-union.com
Achema: Hall 8.0, B80
tion and discharge pipework stay
in place. Only the coupling must be
re-installed and aligned after the
change of cartridges.
The optional installation tool is
consisting of sliding rails running on
antifriction bearings. It allows easy
installation of the cartridge on site in
horizontal position.
The removed cartridge can be re-
furbished with genuine spare parts at
the operator’s workshop or returned
to the factory for inspection.
liner and the rotors comes ready as-
sembled with the mechanical seals,
the bearings, the casing covers and
the timing gears as a ready to oper-
ate “Plug & Pump” Cartridge Unit.
Instead of a time consuming
disassembly of the pump during
overhauls on the jobsite, the entire
cartride can be pulled and replaced
by a new one. The new cartridge is
fitted in following sequences:
During overhaul, the pump cas-
ing, the drive motor and the suc-
platforms. With limited resources of
near-by workshops, skilled labour
and transport, overhauls and repairs
are always a special and time con-
suming challenge.
The new Klaus Union “Plug &
Pump” Design (patend pending) of-
fers a completely new approach to
overhaul and maintenance of Double
Volute Twin Screw Pumps. Contrary to
the conventional Double Volute Twin
Screw Pump Design, the hydraulic
part of the pump consisting of the
FELUWA Pumpen GmbH | GERMANY | [email protected] | www.feluwa.com
YOUR Business – OUR TechnologyMULTISAFE Double Hose-Diaphragm Pumps Handling of abrasive, aggressive and toxic mediaFlow rate up to 1000 m3/h Pressure up to 500 bar
| Reactor, Autoclave, Filter Press and Gasifier Feeding
| Tailings Transfer
| Fly and Bottom Ash Disposal
| Pipeline Transportation
| Wet Oxidation
| Dewatering
Engineered and Made in Germany
Vi
sit u
sJune 15-19, GermanyHall 8.0 | Booth G94
p Global 201526
KNOLLGERMANY
The German pump naufacturer Knoll
will make the modular MX progress-
ing cavity pump toolbox the focus of
its presentation at Achema. The MX
toolbox enables the combination
of the various main components,
including
l pump sets,
l drive variants,
l seal designs, and
l suction housing shapes
across all model series. The wide
variety of the MX pumps thus ena-
bles a precise adjustment of the
pump to the specific requirements of
the task at hand.
In addition, thanks to the easy
replacement of the pump set (rotor
and stator), the delivery rate and
delivery pressure can be adjusted
quickly and economically to current
needs even after the fact. The cur-
rent toolbox system includes the
following:
l Drive variants: servo geared
motor, three-phase geared
motor, geared motor in aseptic
model, Atex drives for Zones 1
and 2
l Seal variants: single or double
hygiene axial face seal with or
without sealing pressure, elas-
tomer bellows axial face seal,
rotary shaft seal and packing
gland optional with flushing
l Housing variants: suction
housing compliant with DIN
11864, DIN 32676, DIN 11851
or EN 1092-1, suction hous-
ing with extended diameter,
rectangular hopper, as well as
with cleaning ports and double
jacket
l Joint variants: cardan joint or
joint with conveyor feed worm
for hopper
l Various pump sets
l Pressure joint variants:
DIN 32676, DIN 11851,
DIN 118654, EN 1092-1 tan-
gential or centric run-out.
This variety of variants for the
initial design and retrofitting of
installed MX pumps will be demon-
strated on a pillar in the Knoll booth
(Hall 9.0, booth E33) at Achema; the
various main components can be
twisted onto one another.
With EvenWall® the prerequisites for high pressures are provided
Knoll MX progressing cavity
pumps are equipped with stators
with EvenWall® technology. Here, in
contrast to cylindrical models, the
metallic stator jacket is adjusted to
the inner contour of the elastomer
and provided with an even elastomer
wall thickness. Depending on the
pump set size, this can be between
4 and 12 mm. This results in
l significantly improved pressure
stability,
l less backflow,
l longer service life,
l better efficiency,
l less shearing of the product,
l better suction behavior and
l the possibility of allowing a
greater temperature fluctuation,
such as due to CIP cleaning,
without change of the rotor.
Helge Kopczak, department
manager at Knoll for the MX and KTSV
pumps, says about these properties:
“EvenWall® is the high-end solution
for stator design. Precisely in the
Individual solutions from the progressing cavity pump toolbox
p Global 2015 27
KNOLLGERMANY
Dry interface allows access to the seal
Völksen continues: “We
have also implemented the
easy-to-loosen interface be-
tween suction housing and rotor
unit between the bearing seat and
suction housing. This ‘dry’ interface
is a unique selling property that
distinguishes our pumps. Thus, if a
pump requires service, the MX op-
erator can easily separate the pump
between the suction housing and
bearing seat; the suction housing
remains unchanged in the process.
The easy pulling away of the bear-
ing seat with geared motor provides
access to the seal without having
to loosen the suction or pressure
side of our pumps. This increases
process reliability and minimizes
downtimes.”
In addition to this module tool-
box for the MX progressing cavity
pumps, Knoll will also display the
KTSV screw pump at Achema. “This
is the KTS screw pump that Knoll has
developed and optimized for pro-
cess-technical applications — hence
the ‘V’. It is used for a wide variety
of products with viscosities from 1
to 2,000,000 mPas. We adjust these
screw pumps individually to the op-
erator’s requirements, so that these
pumps are optimized precisely for
the application in question,” accord-
ing to Schönenberger.
www.knoll-mb.de
Achema: Hall 9.0, E33
rate or the delivery pressure
as needed. The delivery rate of
these Knoll pump sets covers a deliv-
ery range for this single pump model
series from 100 to 5600 l/h with
maximum pressure of up to 40 bar.
The modification can be made
easily and without special tools
thanks to a special interface be-
tween suction housing and the rotor-
stator unit. “Each pump set is adapt-
ed to the suction housing via module
rings. This is the prerequisite for the
after-the-fact pump set change,” ac-
cording to Gustav Schönenberger,
Design Team Manager for progress-
ing cavity and screw pumps. “With
our pumps, the bearing housing is
identical across various configura-
tions. Thus the mounting for the
shaft seal is always the same. This
allows a truly slim spare parts inven-
tory. Our concept also leaves open
the option for replacing an unheated
with a heated pump set. Even if the
operator would like to build a com-
pletely heated pump after the fact,
he can replace the suction housing
with one that can be heated.”
“If the viscosity of a medium
changes a lot in a process, the
pump must be adjusted for this, for
the speed must suit the viscosity.
This is also possible quickly, easily,
and economically with our pumps,
thanks to a replacement of the pump
set,” concludes Völksen.
pletely redesigned and re-procured.
According to Reiner Völksen,
Sales Team Leader at Knoll for the
MX model series with a focal point
on the design of pumps, “The deci-
sive advantage of our MX progress-
ing cavity pump model series is that
you can retrofit our pumps with a
few components and movements.
Regardless of whether you want to
adjust the delivery rate or pressure,
with our pumps it is possible to do
this just by changing the pump set.
For example, you can double the
delivery rate of an MX20 by chang-
ing the pump set 25/10 to the larger
rotor diameter 30/10 with the same
speed. The significant advantage is
that the shaft seal always remains
the same and you do not need to
make any detailed changes. Thus,
this toolbox concept presents a great
advantage when it comes to spare
parts supply.”
“It is therefore possible for
operators to adjust to the changed
parameters with a very simple ad-
justment of the pump set.” Völksen
continues: “A current example from
one of our customers is the adjust-
ment of MX pumps in filling systems
for cleaning products. Thanks to the
easy replacement of the pump set,
the delivery rates were adjusted to
changed package sizes.”
For the MX20 progressing cavity
pump, for example, there are nine
pump set sizes, which allow the
pump operator to adjust the delivery
high-pressure range, this stator of-
fers outstanding advantages. With it,
we can achieve 10 bar per pressure
stage and we are thus well above the
4 to 6 bar commonly available on the
market. With multi-stage construc-
tion, MX progressing cavity pumps
achieve pressures up to 80 bar. In
addition, the tolerances can be ac-
commodated more precisely. In con-
trast to the harsh applications for
progressing cavity pumps, such as
wastewater treatment and bio gas,
media with large foreign bodies are
rare in the chemical, pharmaceuti-
cal, cosmetics, and food industries
and in the manufacturing of colors
and paints. Here, we are ideally po-
sitioned with the EvenWall® technol-
ogy as standard equipment. Even for
high-viscosity media, which require
high pressures in the pipelines, our
MX pumps with the EvenWall® sta-
tor offer the advantage that, thanks
to the high delivery pressure, they
are built much more compactly than
other solutions, some of which have
multiple stages.”
Easy adjustment to changed process parameters
Product change, recipe ad-
justments, process optimization,
changed initial materials — there are
many reasons why the parameters
and thus usually also the require-
ments of the pumps present change
in a process. If you change the re-
quired delivery rate and/or the pres-
sure, the pump must often be com-
p Global 201528
KSBGERMANY
Achema 2015 will see KSB show-
case totally leak-free canned motor
pumps from the Ecochem Non-Seal
range designed to transport haz-
ardous, aggressive, flammable and
explosive fluids. The pumps are
also capable of handling toxic and
extremely hot or cold media as well
as volatile or valuable liquids.
This new type series combines
KSB’s MegaCPK — a standardised
chemical pump successfully em-
ployed for years in process engineer-
ing — with ground-breaking canned
motors built by Japanese coopera-
tion partner Nikkiso. The pumps’ di-
mensions comply with ISO 2858 and
meet the requirements of the DIN/
EN/ISO 15783 and API 685 stand-
ards, with economic operation being
ensured via a new energy-optimised
electric motor design. The low-noise
motor features a corrosion-
resistant can made of Has-
telloy (2.4610).
The new type series
will be available in four
standard variants featur-
ing one design each for
standard chemical ap-
plications, heat transfer
fluids, polymerising or
ferrite-containing fluids
and a special variant for
low-boiling fluids and liq-
uefied gases.
The pump sets have been
designed to meet the require-
ments of explosion protection class
II 2 G c Ex de IIC to ATEX, TR and
IEC Ex and temperature classes
T1 to T5, and can handle fluids
at temperatures from — 40 °C to
+ 400 °C as standard. The maximum
head is 236 m and the maximum
flow rate 690 m3/h, while product-
lubricated plain bearings made of
pure silicon carbide or a silicon-car-
bide-graphite compound allow the
bearing configuration to be optimally
matched to the pump’s operation
and the fluid handled.
If required, the pump casing
can also be heated to avoid a block-
age developing due to fluid cooling
and becoming viscous or solid in
the event of standstill. The motors
are rated up to 75 kW, and with 16
different motor sizes available, the
drive can be precisely tailored to de-
mand. Thanks to the motor bearings’
modular design, the number of parts
requiring storage can be reduced,
cutting warehousing costs.
An E-Monitor available on op-
tion monitors the axial and radial
condition of the bearings, and its
integrated direction-of-rotation indi-
cator eliminates the need for phase
rotation measurements during com-
missioning. As canned motor pumps
operate very quietly, the built-in
operating status indicator provides
a very useful function, especially in
loud environments. Power is sup-
plied to the E-Monitor via the mo-
tor’s terminal box so that no external
cabling is required.
www.ksb.com
Achema: Hall 8.0, H14
New canned motor pumps for chemical and process engineering applications
p Global 201530
Pump coupling opti KTR
GERMANY
On the occasion of Achema 2015 in Frankfurt KTR will not only present
a wide range of solutions for pump couplings, but mainly two solu-
tions which were specifically developed for chemistry and petrochemistry:
l The torsionally flexible shaft couplings for explosion-proof
applications which reliably prevent, as the name ‚Rotex Non Sparking’
implicates, sparks in case of wear of the damping element and
l a simple procedure when replacing the coupling to maintain
compliance.
For pump operators this will mean a significant surplus of safety and a
considerable gain with the service life of pumps, seals and bearings.
We spoke about those items as well as other innovations and further
developments with KTR’s specialists André Artmann and Michael Brüning.
tive nylon coating for metal compo-
nents preventing any kind of static
charging. As a result it is ideally
suitable for hazardous locations and
definitely KTR’s highlight presented
at the Achema 2015. This new ‚Rotex
Non Sparking’ coupling
l is failsafe and maintenance-free
with hazardous locations
l can be operated even with wear
of the elastomer spider
l prevents any generation of sparks
reliably subject to the material
combination metal/nylon.
To ensure the latter, the nylon
coating is highly resistant so that it
is able to continue to transmit the
torque even with total wear of the
elastomer spider installed. Thus, if
the spline of the counter hub supports
the nylon-coated hubs, the pump
driven in this way can be operated
over a certain while without problems
and without any danger of sparking,
even if damping is missing in this
case. Consequently the maintenance
of such pump can be postponed to a
later date without hesitation.
Michael Brüning (l Fig. 2),
KTR Product Manager of flexible cou-
plings, comments on the technical
details: „We have coated the metal
hubs of this coupling with conduc-
tive, highly stiff nylon adapted to the
cam geometry of the Rotex coupling.
In this way it is prevented that steel
strikes against steel if wear is gener-
ated. Moreover, the injection-mould-
ing of the cam geometry provides us
with the option of producing many
other coupling types, for example
with reduced hub for very compact
designs. Customized and shaft-hub-
connections for specific applications
can be realized in this way, too.“
The combination of standard
Rotex components with non-spark-
ing components allows to realize a
wide range of couplings for applica-
Pump coupling opti
Torsionally flexible couplings
type Rotex are characterized by small
dimensions, low weight and a low
flywheel mass while transmitting
high torques. The accurate, all over
machining has a beneficial influ-
ence on the running properties while
increasing the service life of the
coupling considerably. These cou-
plings ensure a torsional vibration-
damping power transmission and
compensate for shocks generated by
motors with irregular operation.
For the new torsionally flex-
ible coupling ‚Rotex Non Sparking’
(l Fig. 1), KTR developed a conduc-
mFig. 1 The new explosion-protected Rotex Non Sparking
in a single-cardanic design with the hub coated on both sides
kFig. 3 With this double-
cardanic Rotex Non Sparking the spacer is coated
p Global 2015 31
service life mizing safety and
KTRGERMANY
tions following the ATEX standard,
comprising the following standard
types, as an example:
l single-cardanic with hub coated
on one or both sides (l Fig. 1)
l double-cardanic with coated
hubs or coated spacer (l Fig. 3)
for large shaft displacements
with low restoring forces al-
lowing for an easy assembly of
standard shell hubs, too.
Compliance is maintained with retrofitting of coupling
With existing systems many
pump operators are afraid of retro-
fitting the pump drive with an inno-
vative coupling solution like, for ex-
ample, the new Rotex Non Sparking,
since this would affect the system’s
compliance. However, according to
the European Machinery Directive
modifications of the original configu-
ration are permissible provided that
a hazard analysis is performed.
André Artmann (l Fig. 4) ex-
plains as follows: „Some pump op-
erators actually perform such risk
analysis if they cannot think of anoth-
er option to get a grip on permanent
bad actors. However, the bureau cratic
burden has often prevented such
retrofitting up to now. That is why we
searched for a way to simplify this
mizing safety and Fig. 2
Michael Brüning, KTR Product Manager
service life
p Global 201532
innovative solutions in a close coop-
eration with excellent support. „Our
strength is the individual solution we
develop in cooperation with our cus-
tomers“, Brüning explains. „In 2014
we moved a big step ahead in manu-
facturing. Today we are in a position
to separate casted components for
couplings with high process reli-
ability. For that purpose we adapted
a procedure which is used success-
fully in the automobile industry, for
example big end bearings. The result
is Rotex S-H with split hubs.“
This coupling which will also be
introduced at the Achema is made
of low-cost cast iron and the hubs
are purposefully separated into
two halves mechanically and with
high process reliability by „crack-
ing“ (l Fig. 5). This results in an
uneven surface with a positive lock-
ing fit ensuring an accurate fit of
the two halves when they are joined
to gether. The contoured, uneven
fracture surfaces ensure the ideal
centring of the hub halves.
Since the hub is split, the
coupling is easy to assemble and
disassemble. „The step towards the
split coupling hub made of cast iron
makes the product pricewise unbeat-
able“, Brüning comments. „Already
in the first year after launching we
could gain many new customers
for this coupling. Particularly for
maintainers this split hub which is
mounted radially in a simple way is
actually a solution of their problems.
The components do not have to be
put apart any longer. This benefit is
even used as a sales argument by
the pump manufacturers.“ l
for all our couplings so that pump
operators are offered the perfect so-
lution for those systems which stand
out by damages of bearing or sealing
again and again, while the fear of a
loss of compliance has prevented an
optimization so far.“
The world’s first split coupling with positive locking
In KTR more than 60 engineers
are working exclusively in develop-
ment and engineering to provide
specifically pump manufacturers
would definitely not make sense to
change the coupling. „If we switch to
a double-cardanic coupling, for ex-
ample,“ Artmann explains, „we will
mostly reach smaller dimensions,
the displacement figures can be
increased, the service life is longer
which means that we can record a
minimized risk in this way. We offer
this risk analysis as a service free
of charge to our customers. This al-
lows the pump operators to retrofit
to safe pump drives with a minimum
of expenses. Compliance is main-
tained which is certified and re-
corded. We can provide this service
hazard analysis in cooperation with
Shell Germany via a form which will
allow us to perform this analysis on
behalf of the pump operators. For that
purpose we made Bureau Veritas, one
of the leading companies in the range
of compliance testing and certifica-
tions assess and confirm this hazard
analysis.“
Features of a coupling which
are relevant for operation and as-
sembly are compared with each
other and an analysis is made if the
risk is minimized, maintaining the
risk either at the same or a higher
level. For the two latter cases it
KTRGERMANY
Fig. 4
required as a service free of
charge to our customers“,
André Artmann, specialist for pump cou-plings and now Sales Manager of Northern
Europe and South Asia, explains.
„This allows the pump operators
Energy effi ciency thanks to modern pump technology
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You save energy thanks to our latest pump technology and clever design. The reduced energy requirement in parallel to increased pump performance lowers the power consumption and so preserves our environment in a sustainable way. Our pumps stand for total environmental awareness.
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Achema 2015
15.-19. June 2015
in Frankfurt am Main
hall 8.0, stand C27
VISIT US
p Global 201534
KTRGERMANY
chemical pumps will be displayed at
Achema 2015.
www.ktr.com
Achema: Hall 9.0, C4
four screws with no need to shift
motor or pump. Two more sizes of
this coupling (l Fig. 6) specifi-
cally for pump drives of standardized
These couplings have mainly
been developed for the use in
pumps and compressors, thus for
applications in chemistry. That is
why KTR had the couplings certified
in accordance with the ATEX directive
94/9/EC.
Part of the special features of
BoWex GT is the simplified assem-
bly: The coupling sleeve is separated
into two absolutely identic shells
which can easily and quickly be dis-
assembled after having unscrewed
Maintenance-free curved-tooth gear coupling
On the occasion of Achema
2012 KTR presented the curved-
tooth gear couplings type BoWex GT
for the first time. This coupling is
characterized, among others, by a
high ease of assembly and thanks
to its double-cardanic design by the
ability to compensate for big dis-
placements. Moreover, this pump
coupling is almost free from restor-
ing forces allowing for a positive
locking torque transmission both
with axial, radial and angular shaft
misalignment. Since BoWex GT op-
erates free from constraints due to
the curved-tooth gear principle even
with radial displacements prevent-
ing edge pressure with angular/
radial displacement, the coupling
minimizes the loads affecting the
bearings and seals in the drive train.
This has a positive effect on the life
cycle cost balance of the overall
system.
nents as well as cooling systems. With its extraordinarily wide product
portfolio the company provides for solutions for a large number of indus-
tries, for example
l Pumps and compressors
l Construction machinery industry
l Agricultural and forestry
engineering
l Machine tools
In less than eight years the specialists located in Rheine, Westphalia
managed to make the business of couplings for pumps and compressors
the second biggest one within the company. The basis of this success are
General Managing Director of KTR and previously CEO of KSB AG, and
André Artmann, specialist for pump couplings and today Sales Manager of
Northern Europe and South Asia. They managed to create an understand-
ing with pump manufacturers, pump operators and service companies
within the supply chain, while they in fact correspond to the character of
A-components. Since the right coupling decides on failures of seals and
bearings, standstill periods, thus have a high share in life cycle costs.
C-components corresponding to the character of A-components
l Materials-handling technology
l Hydraulics
l Wind power technology
l Railway and traffic engineering
l Marine technology
mFig. 5 The Rotex S-H couplings with split hubs are made of cast iron and the hubs are separated
into two halves with a high process reliability by cracking. The uneven surface generated in this way is the ideal positive locking fit.
nFig. 6 „In every single cardan point of BoWex GT the radial displacement is converted into an angular displacement,“
Artmann explains. „In this way shear forces which often damaged bearings and/or seals are eliminated. If these couplings are
used, the service life of adjacent components will automatically rise.“
Schmalenberger GmbH + Co. KGD-72013 TübingenPhone.: +49(0)[email protected]
INTELLIGENT CONTROL CLEVER PRODUCTIONTop class pump technology:
Self priming pump concepts
Compact construction
ISI-System: IE3 motors + frequency convertor
PumpControl
Our Sales pleased to advise you:
NETWORKED PUMP TECHNOLOGY:
Visit us:ACHEMA 2015Hall 9 · Booth B 53
Pump technology of the fu
ture
We are ready:Industry4.0
Lise-Meitner-Allee 20D-25436 Tornesch/HamburgTel.: + 49 (0) 4120 706590Fax: + 49 (0) 4120 7065949 [email protected]
www.witte-pumps.de
Leading Gear Pump Technology since 1984
Lise-Meitner-Allee 20D-25436 Tornesch/Hamburg
Tel.: + 49 (0) 4120 706590
Fax: + 49 (0) 4120 7065949
www.witte-pumps.de
Gear Pumps for transfer and metering in the chemical processing industry.
WITTE CHEM - Gear Pump Series
Special design for chemical applications
and well suited for use with corrosive or
The multitude of available materials for the
core components like gears and bearings of
the WITTE building block system guarantee
Spec.displacement
volume:: 0,2 cm3/rev
up to 12.000 cm3/rev
Viscosity: up to 1.000.000 mPas
Temperature: up to 580 °F
Suction pressure: Vacuum up to 215 psig
Intermediate sizes with narrower gears for
high-pressure applications are also available.
VISIT US ON ACHEMA
Hall 8, Booth F 36
Scan for
more information
about CHEM Series
ABEL GmbH & Co. KGAbel-Twiete 1 • 21514 Büchen Tel.+49 (41 55) 818 - 0 www.abel.com • [email protected]
Membrane PumpsSolids Handling PumpsHigh Pressure PumpsMarine Pumps
Energy saving pumping solutions for the chemical industry.ABEL can make your conveying process
pump technologies. Stop by our booth at the ACHEMA for your FREE Energy Savings Report and let ABEL show you the map to savings.
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Hall 8 / Booth H47
p Global 201536
for API applications
New screw pump LEISTRITZ
GERMANY
New screw pump
Peter Bader
With the recently released L3MA se-
ries of triple screw pumps German
Leistritz Pumpen GmbH presents a
new series of pumps designed to
comply with API 676 3rd Edition.
API 676 — Positive Displacement
Pumps — Rotary, 3rd Edition, Nov.
2009, is a standard put forth by
the American Petroleum Institute. It
covers the minimum requirements
for rotary positive displacement
pumps for use in the oil & gas,
petro chemical, and chemical indus-
tries.
Triple screw pumps are self-
priming rotating positive displace-
ment pumps suited to handle various
oil types and other liquids with a min-
imum lubricating quality. The design
simplicity makes these screw pumps
intrinsically reliable and efficient.
Only three moving parts — a driving
spindle and two idler spindles—ro-
tate inside a casing with close toler-
ances, so forming sealed chambers
and provoking the axial displacement
of the fluid. The idler spindles rotate
without contact with the driving spin-
dle because of the fluid itself. The
accurate hydraulic balance and the
special profile of the screw thread
guarantee a continuous flow with
for API applications
mFig. 1 3D Graphic of the new L3MA Pump
lFig. 2 The L3MA built
in a lube oil skid.
LEISTRITZGERMANY
minimum pulsations and turbulence, resulting in
extremely low noise levels even at high rotational
speed.
The L3MA Features
The new pump has no separate steel casing
with an internal liner for the screw spindles to
run in. A new spindle material makes it possible
to have the spindles run directly in a steel cas-
ing and avoids an expensive construction with a
coating in a separate liner.
Only three static seals, executed as O-ring
seals instead of flat gaskets, are used. This
eliminates the risk of leakage due to insufficient
compressed flat gaskets. A single balanced act-
ing mechanical seal has been chosen as shaft
seal which proved itself in thousands of appli-
cations. A cartridge seal can be provided as an
option.
Suction and discharge flanges are accord-
ing to ANSI B 16.5 class 300 lbs. The L3MA
pump series is available in 12 different frame
sizes with defined rotor pitch angles. The maxi-
mum operating conditions of the pump are de-
fined with a max. flow rate of 276 m3/h, a dif-
ferential pressure of 20 barg and max. speed of
3600 rpm. A minimum viscosity of the pumping
fluid should be around 10 cSt to secure always
the required lubrication.
www.leistritz.com
Achema: Hall 8.0, F93
l No special internal coatings required
l Axial inlet for ease of piping
l Single bearing
l Single mechanical seal subjected only to
suction pressure, API 682 cartridge
l Seal optional
l Hydro-dynamically balanced rotors —
no thrust bearing required
l Quiet operation — no pulsations
l Low fluid shear
l High reliability/long service life/
low maintenance
l Low NPSH requirement
l Handles entrained gases
(advantage vs. centrifugal)
l High volumetric efficiency
Further technical highlights are
THE ENDURERSFOR EXTREME DUTY POWER TRANSMISSION:OUR ZERO MAINTENANCE DISC PACK COUPLINGS.
THE COUPLING.RW-COUPLINGS.COM
p Global 201538
LEWAGERMANY
With two current developments that could hardly differ more, Lewa GmbH,
a pump and system manufacturer based in Leonberg, Germany, reinforces
its reputation as a leading supplier of metering and process diaphragm
pumps: The Intellilab (l Fig. 1), a laboratory pump specially made for
technical centers, enables new processes and products to be developed
safely and reliably at pressures up to 500 bar. The hermetically sealed high-
pressure micro-metering pump is equipped with the latest drive and control
technology and has been available since January 2015. Unlike the Intellilab,
which enables reproducible metering of even the smallest quantities, the
G3M (l Fig. 2) is a robust workhorse for use in the chemical industry or
on offshore platforms. In addition to the triplex drive unit, which has been
on the market for about a year, Lewa is currently working on developing a
suitable line of pump heads. Initial orders have already been received for
both products.
the fluid is hermetically blocked
against atmosphere and the dis-
placement hydraulic system. Leak-
ages to the outside and the fluid
coming into contact with air are elim-
inated by the hydraulically coupled
metal diaphragm, which is particu-
larly well suited for metering small
flows. The pressure stiff hydraulic
actuation and the intelligent control
of the pump also keep the impact of
the pressure on the metered flow to
a minimum.
The special operation of the ser-
vomotor allows the pump in the table
housing to be capable of generating
low-pulsation volume flows. At a dis-
charge pressure of up to 500 bar, flow
rates between 10 and 500 ml/h at an
accuracy of ±1 percent are possible.
In automatic mode, the pump can be
controlled from a DCS via an analog
signal (0/4–20 mA). A new interface
is also well matched to the special
requirements in high-pressure labo-
ratories. In combination with various
closed-loop control structures, the
fluid kinematics can be adapted to
the requirements of the process and
the profile of the metered flow can be
modeled in nearly any way. In doing
so, the stroke volume (for example)
can be filled with the conveyed me-
dium, which is then gradually and
continuously displaced. Metered flow
profiles can also be programmed and
run in a controlled manner. The in-
put and visualization are carried out
via a color touchpad with intuitive
usability.
From the rugged process diaphragm pump to the high-precision micro-metering pump
The Intellilab is a logical evolu-
tion of the K3 and K5 micro-metering
pumps. The tried-and-true technol-
ogy was retained and enhanced by
adding the latest drive and control
technology, Lewa Intellidrive. This
technology controls the drive-side
angle speed dynamically during
operation. Unlike piston pumps,
which can also operate under high
operating pressure, the hermetically
sealed micro-metering pump is not
subjected to natural leakage. This
is an advantage, particularly when it
involves dangerous substances, not
even a tiny drop of which may escape
outside.
The Intellilab is primarily used
for accurate and reproducible meter-
ing in high-pressure synthesis and
hydration processes and within the
framework of mini-plants, because
mFig. 1 At a discharge pressure of up to 500 bar, flow rates
between 10 and 500 ml/h at an accuracy of ± 1 percent are possible. Various closed-loop control structures allow the fluid kinematics to be adapted to the requirements of the process and the profile
of the metered flow can be modeled in nearly any way.
p Global 2015 39
LEWAGERMANY
that regulates the change of the mo-
tor RPM, the number of strokes per
minute and thus the flow rate. Be-
cause all components are designed
for continuous duty, trouble-free
operation over 40,000 h is possi-
ble. Lewa drive technology has been
used for decades in such widely dif-
fering climate zones as the Arctic,
the tropics and desert regions.
New pump head family for all common applications
To fit the G3M, which can man-
age a maximum pressure of 750 bar
and a flow rate of approximately
50 m³/h, Lewa is also currently work-
ing on pump heads for every conceiv-
able application. The development
is based on existing and proven
technologies. The objective is to be
able to offer a complete series of
pump heads by the end of the year,
which can be matched perfectly to
the respective specific application.
Even high-pressure applications will
be possible with the M800 pump
heads, because the heads on the
G3M are designed for up to 750 bar.
For this year, Lewa also wants to of-
fer a synchronization of up to three
G3M pumps—as it is already possi-
ble for the other triplex models. The
objective is to reduce the pulsation
of the pumped liquid.
www.lewa.de
Achema: Hall 8.0, C62
piece, solid and triple-throw crank
shaft that requires only two roller
bearings. To attain better damping
of the swelling load, the bearings of
the connecting rods are designed as
friction bearing. Because an external
lubricating oil supply would be too
susceptible to problems, Lewa tri-
plex drive units lubricate the moving
parts via an oil bath or splash lubri-
cation.
As with other Lewa triplex drive
units, the primary applications of
the G3M are in the oil and gas indus-
try as well as the chemical process
industry. The chief application in
the oil and gas industry is injecting
monoethylene glycol and methanol.
In the process industry, a wide va-
riety of pumping tasks in pressure
ranges between 40 and 750 bar can
be managed with ease, including
vinyl acetate, slurry in wet oxidation
or high-pressure metering of liquid
ammonia. The flow rate can be con-
trolled using a frequency converter
The highly explosive gas re-
quired an absolutely leakproof spe-
cial design that withstands both low
temperatures and high pressure,
especially considering the transport
ships are dry docked for mainte-
nance only once every five years. In
implementing this solution, Lewa
relied on its experiences in the de-
velopment of the sister models.
The G3M is an intermediate size
with a stroke length of 120 mm. It
combines the positive features of the
other types. At a rod force of 125 kN,
a maximum output of 200 kW is at-
tained. Like all other models, the
newcomer to the portfolio features
a constant stroke length and is
designed with an integrated heavy-
duty worm gear. The monoblock drive
element housing with flanged-on
electric motor allows a design with
a minimum number of bearings and
sealings. A highly compact machine
is the result. The perfect phase offset
of the pistons is ensured by a one-
Rugged and compact design for trouble-free operation for over 40,000 h
The G3M, a heavy-duty, medi-
um-sized triplex drive unit, was origi-
nally developed to bring re-liquefied
boil-off gases to a high pressure
level, rendering these gases usable
for the engine of the LNG tanker. This
option is of interest not only because
the engine efficiency is much higher
compared to heavy fuel oil (HFO), but
also because environmental impact
can be drastically reduced by its use.
For example, NOx values are reduced
by 85 percent and SOx values are
even reduced by 100 percent.
kFig. 2 The G3M, a triplex drive unit made by Germany-based plant manufacturer Lewa, has a robust and low-maintenance intermediate size. This year, the manufacturer plans to add
a matching pump head series to the product line.
Motor-inverter makes it possible
The ErP directive allows the combi-
nation of IE2 motors with inverters
as an alternative to IE3 premium
efficiency motors. The purpose of
an integrated motor-inverter is to
save time and reduce costs in sup-
plementary material (wires and
racks mainly), study, installation,
programming and testing of the mo-
tor and inverter system, as well
as the dangers due to errors
associated with these
operations.
Therefore Motive developed the
patented, easy to program, easy
to use inverter with additional
analogic switch and knob,
IP65, with removable keypad,
remotable wireless, powered
by induction when placed in
its housing on the motor or
by lithium rechargeable bat-
teries. This inverter is designed
as a user-friendly turnkey inte-
grated system, with all parts,
motor, inverter and control
designed for outdoor use, and
with standard remote control.
The manufacturers of pumps
can thus offer a finished “plug-in”
product, without delegating risky
and costly installations to pump us-
ers. These need only to insert the
plug, wherever it is installed, and
decide if they want to bring the key-
pad with them.
www.motive.it
MOTIVEITALY
Frankfurt am Main · 15 – 19 June 2015
Be informed. Be inspired. Be there.
➢ World Forum and Leading Show for the Process Industries
➢ 3,800 Exhibitors from 50 Countries
➢ 170,000 Attendees from 100 Countries
www.achema.de
p Global 2015 41
with the new solenoid driven metering pump
New standards in accuracy and reliability
PROMINENTGERMANY
New standards in accuracy and reliability
with the new solenoid driven metering pump
The German manufacturer ProMinent developed a new metering pump for metering between 2 l/h and 45 l/h at a back pressure of 25 bar to 2 bar. As the successor to the solenoid driven metering
pump gamma/ L, it features a modern design with new electronics and many new functions. In particu-lar it offers a precise, low-wear solenoid drive, predictive control technology and intuitive operation. The gamma/ X independently ensures a smooth metering process at any time, massively improving the efficiency and accuracy of the capacity.
The gamma/ X is the first meter-
ing pump in its class to be driven
by a cleverly controlled solenoid. Its
innovative control technology gives
the new pump an important advan-
tage over conventional technologies.
Its model-based solenoid control
detects pressure variations and
protects the system against over-
pressure without the use of addi-
tional sensors. The stroke length can
be electronically set at between 0 and
100 %. Continuous metering charac-
teristics in the form of an elongated
metering stroke are beneficial with
volume-proportional metering of a
chemical into a primary flow, as they
ensure good mixing and there is no
need for a static mixer in the primary
flow. For the customer this means in-
novation in metering and production
processes.
Easy installation
Users benefit even at the instal-
lation stage: a standard tool is used
to fix the new solenoid driven me-
tering pump to the mounting plate.
There are also virtually no restric-
tions in terms of installation and
42 p Global 2015
PROMINENTGERMANY
ous scrolling through the various
operating layers, enabling intuitive
operation and programming of the
new gamma/ X: the capacity can be
quickly and simply adjusted in litres
per hour.
Stroke, stroke rate and meter-
ing profile are all freely parameter-
isable. A pressure display provides
information about the existing pres-
sure levels by the operator glancing
briefly at the screen. The three-level
LED status display on the front of
the unit is easy to read from a dis-
tance and from all angles, clearly
indicating the current operating
status, thereby guaranteeing an
overview of the current operating
status at any time.
Increase effective-ness, reduce costs
When in operation, the new
solenoid driven metering pump
gamma/ X detects varying pressure
levels, and fully automatically and
precisely adjusts its metering be-
haviour to the prevailing conditions.
Automatic bleeding optimises the
metering result when metering is
affected by gas bubbles pro-
duced by gaseous media. The pump
also adjusts its metering behaviour
with high-viscosity media. The intel-
ligent control technology works fully
automatically to ensure a smooth
metering process, enabling produc-
tivity and product quality to be in-
creased. And its service module also
indicates when the pump occasion-
ally needs maintenance.
Hydraulic deviations detected without the need of sensors
Its innovative control technology
gives the new pump an important
advantage over conventional tech-
nologies: its sophisticated solenoid
control detects hydraulic deviations
that can have an adverse effect on
the metering task. Overpressure,
ruptured discharge lines or negative
pressure and gas in the dosing head
are all detected without the need for
an additional sensor in the dosing
head.
The gamma/ X shows the cur-
rent pressure on its display. In the
event that the pump exceeds or
undershoots pre-set limit
values, an alarm be-
comes visible in the
display, which can
be transmitted via
positioning, as the status LED can
be easily read from all angles. The
clearly arranged pin configuration
prevents incorrect assignment. Op-
erating elements, simply accessible
from the front, as well as clear mes-
sages on the large display guarantee
fast maintenance.
Intuitively operated
The gamma/ X is fitted with a
large illuminated graphic display
with plain text in a number of lan-
guages. Parameters can be quickly
adjusted using the newly developed
Click Wheel. Four keys ensure fast
access without the need for labori-
p Global 2015 43
PROMINENTGERMANY
excessively strong pulsations of the incompressible
metering liquid. The gamma/ X masters all these ap-
plications with aplomb. If low-pulsation or continu-
ous metering is called for, the compression stroke
can be performed correspondingly slowly on the
gamma/ X due to the controlled solenoid drive.
www.prominent.com
Achema: Hall 8.0, J64
The stroke length can be electronically set at
between 0 and 100 %. Continuous metering charac-
teristics in the form of an elongated metering stroke
are beneficial with volume-proportional metering of
a chemical into a primary flow, as they ensure good
mixing and there is no need for a static mixer in the
primary flow. Low-pulsation metering characteris-
tics can also be necessary with rigid metering lines,
to prevent damage to the pipework or the pump by
relays or the bus interface, thereby preventing
damage through early detection and shut-down
of the system and pump.
Safety without the need for additional components
The integral pressure monitor is a reliable
back-up system for the existing manometer and
pressure relief valve. Showing the pressure on
the display simplifies commissioning, monitor-
ing and troubleshooting.
The three-level LED status display on the
front of the unit is easy to read from a distance
and from all angles, clearly indicating the cur-
rent operating status and guaranteeing fast
and clear detection — regardless of the instal-
lation location — from any position. There are
therefore virtually no restrictions in terms of
installation and positioning.
The optional diaphragm rupture sen-
sor guarantees additional safety and triggers
an alarm, resulting in the metering pump
switching off in the event of a simultaneous
fault indication.
Higher product quality through seamless metering processes
Its model-based solenoid control detects
varying pressure levels and fully automatically
and precisely adjusts its metering behaviour to
the prevailing conditions. Automatic bleeding
optimises the metering result when metering
is affected by gas bubbles produced by gase-
ous media. The solenoid driven metering pump
gamma/ X can protect the system from over-
pressure, as it detects all pressure deviations.
The operating range extends from 1 ml/h
to 45 l/h, the adjustment range is 1:2,000 and
reproducibility of accuracy is +/– 2 %.
Dickow Pumpen KGSiemensstraße 22, D-84478 WaldkraiburgPhone 08638/602-0, Fax 08638/602-200E-Mail: [email protected] · [email protected]: http://www.dickow.de
The new GML Gear Pump withMagnet Coupling and TuthillGlobal Gear combines decades ofexperience and offers unparalleledperformance and reliability.
June 15 - 19 Hall 8 / D54
New ProductNew Product
44 p Global 2015
energy saving
The importance ofThe importance ofSAERITALY
SAER, with more than 60 years of
experience in water field, invests
more than 6 % of his annual turno-
ver in R&D whose aim is to reduce
wastage of water and energy and
enhance productivity. The company
offer pumps with a complete range
of operating options, variable speed
running for applications such as
l general irrigation,
l water intake and distribution,
l drinking purposes,
l agriculture,
l industry,
l HVAC,
l power generation,
l municipalities,
l mining,
l off shore,
l naval groundwater supply,
l pivot feeds, etc.
Water has to be treated accord-
ing to its final use. SAER pumps are
constructed for extended operation
in the toughest environments from
corrosion-resistant Duplex or AISI
316 Stainless Steel or Bronze Marine
as appropriate — and customization
isn’t a problem: recently the com-
pany inaugurated a new Division
for Big Projects where the qualified
staff is able to drive in the selec-
tion of tailored solutions. All styles
can be customized to suit the exact
application with the warranty of
100 % Italian origin and quality. Over
2,000 types of pumps are made in
5 metallurgies, with one of the best
delivery time on the market: the
average, doesn’t matter the size of
the pump, is 10 working days.
The range includes SKD Split
casing pumps (up to 5,000 m³/h),
TM multistage pumps (up to
64 bar), NCBK end suction pumps
(2,500 m³/h max flow) submers-
ible, monoblock and residential
pumps, booster sets and surface
mFig. 1 Installation of a 14 inches submersible pump and motor.
energy saving
nFig. 2 SAER end suction pumps.
SAERITALY
supply. Due to its enduring
magnet motor and its inverter
driver, the SL Solar System
ensures even water distribution
to all areas, even where there is
little or no power supply.
l T-One exclusive electronic pres-
surization system with innova-
tive technology maintaining a
consistent delivery of pressure,
regardless of the demanded
flow, ENERGY SAVING because
of its automatic regulation.
Pump systems can also be
supplied with a dry run protection
system, to avoid damage to pumps
from loss of prime situations.
SAER is also provided with two
state of the art testing room for the
test of pumps and motors, both sur-
face and submersibles. All the pro-
duction is tested inside the facilities
and also third part witnessed tests
are performed, with international
certifications bodies too.
www.saer.it
and submersible motors up to
400 HP.
The Italian manufacturer has
further increased it’s huge range of
pumps and motors. Efficient, save
and quality technology: these are
the keywords for further innovations
totally made in Italy:
l Latest series of submersible
pumps from 6” up to 12” at
highest efficiency, series VS,
available in Stainless Steel
AISI 316, Bronze marine,
Carbon steel and DUPLEX. With
such a choice the applications
are wides: Oil&Gas, mining,
agriculture, civil, industrial etc.
l range of surface motors from
7.5 kW to 55 kW 2-pole and
4-pole with IE3 efficiency levels,
both for monoblock pumps and
normalized.
l With a view to achieve sustain-
able growth, SAER has devel-
oped SL Solar, the ultimate
solar powered system for water
Pumps and Valves - Experience, Responsibility, Passion.
www.klaus-union.com
made in Germany
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
ww
w.ic
d-m
arke
ting.
de
p Global 201546
SCHMALENBERGERGERMANY
Stepping up the pressure with self-priming centrifugal pumps
Dietmar Rogg
Among the outstanding properties
of these self-priming pump series is
the capacity for sucking in contami-
nated oils and emulsions with high
air content. Now Schmalenberger is
presenting several more additions
to its existing range of these ultra-
efficient pumps.
A completely new concept is
represented by the multi-stage self-
priming KSP centrifugal pump. Up to
now this pump series was designed
just for use with low pressures and
large flows. As a result of its variable
modular system, the KSP can now
cover the higher hydraulic ranges
of up to 10 bar pressure, as well as
handling lower flows of 20–160 l/
min. The manufacturer has achieved
this by a combination of different
pump hydraulics and the multistage
configuration within a single unit.
This extends the range for use in
industrial applications, making it
perfectly suitable for supply to filter
systems and pumping of coolant
fluids in the machine industry. The
high hydraulic efficiency of this
pump series guarantees highly effi-
cient energy consumption.
In order to meet international
conditions and the various associ-
ated energy requirements (e. g. of
the IE3 class), the series of self-
priming pumps has now been ex-
panded with the addition of a new
docking module. This offers the pos-
sibility of installing standard mo-
tors of various international manu-
facturers. Here Schmalenberger is
responding to extended customers
requirements, so that not only Eu-
ropean but also American and Chi-
nese standards of efficiency can be
complied with — without however
any compromises being made in
terms of the versatility of the prod-
uct series.
And Schmalenberger has taken
another step forward with its SMK
pump. This model can be supplied
together with an innovative ISI (Inte-
grated Simple Inverter) system. The
SMK is also capable of pumping liq-
uid and gas mixtures with an air ra-
tio of 15 %, works in slurping mode
and is self-priming for up to 3 m.
Ideally it should be installed above
medium level. Due to the open ge-
ometry of the impeller, it can handle
solids up to a size of 5 mm. The SMK
is made of corrosion-resistant and
highly durable plastic. With its low
weight and compact design, the
pump is easy to install. Further ben-
efits are low noise level and reduced
vibrations. The SMK can handle
flows up to 55 m³/h, with a pressure
of 1.7 bar.
The ISI system is a high-tech
motor control system, characterised
by a space-saving design of both mo-
tor and inverter. The electronic com-
ponents are built into a robust die-
cast aluminium housing. Notable
benefits are the ease of installation
p Global 2015 47
SCHMALENBERGERGERMANY
with or without a display screen. For
example, the SMK’s integrated field
bus interface (ProfiNet, Profibus,
CAN Open) means that it can easily
be linked to various automated sys-
tems. Additional product-integrated
analogue and digital interfaces are
available upon request.
www.schmalenberger.de
Achema: Hall 9.0, B53
motors of past decades, to the per-
manent magnet motors that are in
demand today and even the reluc-
tance motors that stand for the fu-
ture. Due to its streamlined design,
the entire ISI system can hardly be
distinguished from the traditional
and familiar electrical motor. The ISI
controls include interfaces and func-
tions for the processing of standard
signals and can be supplied either
bly. The integrated inverter software
is designed to handle both current
and future motor systems — from
the tried and tested asynchronous
and ease of operation, based on an
intuitive operating interface, whose
robust buttons enable the pump set-
tings to be adjusted swiftly and relia-
n
The SMK pump with an innovative Integrated Simple Inverter
www.ktr.com
Thanks to new material and production technologies the fail-safe ROTEX® Non Sparking can continue to operate if the spider has worn off with no danger of sparking, ensuring a carefree operation in hazardous locations.
More safety for hazardous locationsHall 9.0 Booth C4
ti
In this YouTube movie you will get
details about a self-priming sewage
pumps for clean and polluted
liquids or media with gaseous
inclusions. Fields of application:
coolant supply, environmental protection technology,
surface technic, water supply and -filtration.
p Info-Plus
p Global 201548
More than 40 ye SEKOITALY
Established in 1976, Seko S.p.A.
is a leading manufacturer of
metering pumps and dosing sys-
tems. His long activity allowed Seko
to acquire a vast experience
in diversified applications
and reliable solutions for
the dosage and injection
of chemicals, maintaining
an efficient control of the
related process parameters.
Today Seko is an Interna-
tional Group operating with
three business units each one
designing and man-
ufacturing selected prod-
uct lines for dedicated markets
with different applications on
customer specifications.
Process & System
Seko P&S business unit
was born in 2002 after the merge
between Seko Italia S.p.A. and Bono
Exacta S.p.A. active in the oil & gas
industry since 1958. This operation
has expanded the product range,
its expertise and has immediately
given the “entry pass” to the oil &
gas market.
This business unit currently de-
signs, produces and supplies pumps
and systems to oil & gas, energy,
chemical and petrochemical, food
& beverage, ceramic, pharmaceuti-
cal, paper and textile industries. It
is able to provide a qualified support
on commissioning and start-up on
pumps and systems, an assistance
for maintenance activities and spe-
cific “on job” trainings for End-Users.
The product range is composed of
l plunger metering pumps,
l mechanical diaphragm meter-
ing pumps and
l hydraulic diaphragm metering
pumps.
Seko P&S provide even chemi-
cal injection packages completely
designed and manufactured under
customer specifications (l Fig. 1).
To be closed to the Middle Easter
End-Users a specific site is located
in UAE.
Main products of the P&S unit
are
l plunger and
l hydraulic double diaphragm
metering pumps Nexa Series
(l Fig. 2).
Designed according to the API
675 standards, this series is char-
acterized by flexibility and modular-
ity of combining different metering
units, even on site. The specific
design tailored on customer speci-
fications is our “daily job”. The
compliance with ATEX European
Directive makes SEKO pumps suit-
able for being installed in classified
areas.
Seko P&S is ready to introduce
a new high pressure pump — the
BN pump’s model is an extension of
Nexa series working at a discharge
pressures up to 350 bar gauge.
Designed according to API 674
Standards, Triplex series has spe-
and
rFig. 1
Chemical Injection package
p Global 2015 49
SEKOITALY ars in metering
allows these pumps to be installed
in hazardous areas.
The mechanical diaphragm and
plunger pumps Exacta series with
spring return mechanism are a solu-
tion for industrial application where
chemicals have to be pumped l
is designed according to the API 675
Standards. This pump is suitable for
those applications requiring high ac-
curacy. The possibility of construction
with various materials allows these
metering pumps to satisfy every ap-
plication where safe and reliable
dosage is a must. Their compliance
with the ATEX European Directive
qFig. 2 Nexa Series—
API 675 plunger and hydraulic double diaphragm
metering pump
dosingcific design of the mechanism which
allows the pump to operate at a very
low speed without forced lubrication
where a slow plunger motion
is required e.g. to avoid cavi-
tation when pumping viscous
liquids, hot products or liquids
have a low vapor pressure.
The pump can be designed to
be remotely or automatically
controlled to meet the process
needs.
The hydraulic diaphragm
metering pumps Nyva series
50 p Global 2015
Cleaning & Hygiene
Seko C&H business unit
occupies a prominent position
in the global market for cleaning
and hygiene solutions. The company
is the world’s largest manufacturer
of peristaltic pumps for commercial
laundry and ware washing applica-
tions. Seko C&H is the market leader
for integrated pumps in commercial
dishwashers, with market share of
over 80 % in Europe.
The blue peristaltic pumps
from the PR series are now consid-
ered an international standard and
have gradually come to epitomize
peristaltic pumps in general. Dosing
systems from the Smart series are
used in machines with a capacity
up to 100 kg. Motor-driven
pumps such as those from
Spring series are used in
larger machines and tun-
nel systems.
www.seko-group.com
Achema: Hall 8.0, J63
cal and physical parameters
in industrial processes. The
instruments are completed by
sensors and accessories ena-
bling them to be installed in
any application.
l Swimming pool dosing sys-
tems
driven pumps features a high
level of reliability and accuracy
guaranteeing excellent quality.
Three sizes of mechanism and
a wide selection of models with
different performances allow
the user to find the appropriate
solution for almost any ap-
plication.
l Measure and control instru-
ments for monitoring chemi-
safely. Its low maintenance cost is
one of the main reasons to choose
these models.
Water & Industry
Seko W&I business unit of-
fers a complete range of products
for measuring and monitoring the
chemical and physical properties of
water. A whole range of accessories,
such as tanks, stirrers, water meters
and level probes, complete an ideal
installation. W&I currently supplies
its products for the treatment of pri-
mary water, waste waters, industrial
processes, swimming pools, cooling
towers, agriculture, fertilizing and irri-
gation. Main products of W&I unit are:
l Solenoid dosing pumps: The
construction technology and
the great chemical compat-
ibility of the components make
these pumps extremely precise
and versatile. Thanks to their
microprocessor-based electron-
ics, they adapt easily to any
dosing requirement.
l Motor driven pumps: The
spring return range of motor
SEKOITALY
nFig. 4 Nyva Series—API 675 hydraulic
diaphragm metering pump
rFig. 3 Triplex Series—API 674
three plunger reciprocating pump
LEISTRITZ PUMPEN GMBH
The Screw of Archimedes
L3 Triple Screw Pump
L4 Twin Screw Pump - Double Volute
L2 Twin Screw Pump - Single Volute
Markets & Industries
L5 Five Screw Pump
Tradition meets Innovation
Leistritz Pumpen GmbHMarkgrafenstrasse 29-39 | D-90459 NurembergPhone: +49 (0)911/4306 - 0 | Fax: +49 (0)911/4306 - 490E-Mail: [email protected] | www.leistritz.com
Capacity max.: up to 22,000 GPM (up to 5,000 m3/h)
Differential Pressure max.: up to 4,060 psi (up to 280 bar)
Leistritz Screw Pumps and Systems
Leistritz Pumpen GmbH, with its headquarters in Nuremberg/Germany, has been producing Screw Pumps since 1924. Latest Technology in combination with strictly controlled quality is the basis for the globally
Leistritz serves all kind of markets and applications.
Please visit us at ACHEMAHall 8 / Stand F93
BUNGARTZMASTERPIECES
SEAL OF TRUTH
Representing the groundbreaking special centrifugal pumps from the Bungartz collection, series production
As a leading representative from the era of long-lasting creations, we present the horizontal centrifugal pump M-UMOR. Its hydrodynamic seal shines thanks to its complete safety. Possible explosions are nipped in the bud, so it‘s perfect for abrasive and volatile media. A magnificent acquisition!
More under 0211 57 79 05 - 0 and: www.bungartz.de/masterpieces6
Visit us at ACHEMA 2015, Hall 8, Stand C 1
p See us in Frankfurt Hall 8.0, Booth L94
p Global 201552
SCHROEDERGERMANY
A valve for high pressures and all load conditions
Schroeder Valves has developed a
new automatic recirculation valve
for high and very high pressures.
To to ensure the highest degree of
quality and functionality, the com-
pany is currently constructing a test
stand for pressures up to 400 bar.
Schroeder Valves has devel-
oped a new automatic recirculation
valve for high and extremely high
pressures, which also works reli-
ably under highly fluctuating load
conditions: the SHP-series auto-
matic recirculation valve. With the
innovation, the specialist in pump
protection valves is responding to
the requirements of its customers,
primarily from the field of power
plant and plant construction and the
offshore industry.
“The SHP takes the general
development of higher pressures
and temperatures and the in-
creased energy-efficiency require-
ments into account,” explained
Axel Mücher, managing partner
at Schroeder Valves. “Alongside
this, the changing way in which
plants work was also taken into
consideration in the development
of the SHP. Special load sequence
power plants, such as modern com-
bined cycle power plants and coal-
fired power plants, are operated at
partial load for a large proportion
of their operating time, on account
of the increasing high proportion of
regenerative energy generation and
highly fluctuating load conditions.”
The SHP is the ideal minimum
flow device for these conditions:
Thanks to multi-stage pressure re-
lease control over the entire mini-
mum quantity range, wear is mini-
mised — even in the case of long-term
partial load operation. The particu-
larly wear-critical area near to the
bypass closing point in the bypass is
automatically overdriven by the con-
trol characteristics, without the range
of movement of the equipment being
limited. The shut-off for the bypass
function and the pressure reduc-
tion function are clearly separated
in terms of location. Furthermore,
the shut-off element for the bypass
has no throttle function whatsoever.
Thus, the seal of the bypass is not
affected should limited wear occur to
the pressure-reducing components
during operating time. The radiation
of the sealing surfaces, which can
ultimately lead to the total failure
of the sealing function, is safely
avoided. Furthermore, the seal seat
is located in the direction of flow,
upstream from the flow-regulating
fittings and thus in the area of high
static pressure, and consequently
far removed from the cavity-suscep-
tible pressure level at the end of the
throttle section.
Schroeder Valves has each valve
undergo a 100 % pressure and func-
tionality testing prior to delivery. To
ensure this also with the SHP, the
company is currently adding to their
flow test center a test stand for pres-
sures up to 400 bar.
The SHP builds on exist-
ing Schroeder Valves
technology. The
company already
has years of op-
erational experience
with almost all of the
effective principles and as-
semblies used. As such this can
be considered ‘Proven Equipment’.
The individual system components
have simply been modified and in-
novatively combined, as such that
they enhance the dependable and
low-wear area of application of the
existing technology to meet the in-
creased requirements. Thus, the
new SHP-series automatic recircula-
tion valve enables and promotes the
energy-efficient operation of modern
power plant facilities.
www.schroeder-valves.com
Achema: Hall 9.0, E59
The Schroeder High Pressure Valve
(SHP) is an automatic recirculation
valve for high and extremely high
pressures, which also works reliably
under highly fluctuating load conditions.
See more details in this video.
p Info-Plus
p Global 2015 53
is able to offer complete dosing sys-
tems, including control technology
for automated work processes.
In the seventies, another impor-
tant milestone in the dosing indus-
try was the development of the KKV
pump (Klotz Kaltverweil method) for
textile dyeing, which was so success-
ful that it continues to be used by
the textile industry all over the world
today, now updated with state-of-
the-art technology.
sera’s latest technical achieve-
ments include the following pumps
which were exhibited at this year’s
Achema:
l The new sera iStep diaphragm
dosing pump, which combines
an intelligent drive concept with
the accuracy of a diaphragm
dosing pump and thus sets new
standards in terms of accuracy
and reliability.
l The new ecoBlue solenoid dia-
phragm dosing pump, which
offers more than quality and
reliability, is economical from the
start and covers simple solutions
in the area of chemical dosing.
l The new sera R509.1 distin-
guishes itself with a highly ac-
curate dosing capability even for
high flow rates with high counter
pressures and is used, for exam-
ple, for the addition of additives
in the petrochemical industry.
www.sera-web.com
Achema: Hall 8.0, K63
From baking trays to dosing specialistCommitted to tradition, the name
sera (Seybert & Rahier) has stood for
quality, innovation, competence, reli-
ability, efficiency and flexibility since
it was established in May 1945. After
initially manufacturing household
utensils (baking trays, pots, ladles,
cake tins and smokers) and repairing
agricultural machinery, the range was
expanded to include more technically
sophisticated products, such as dry
sterilizers, multifunctional chemical
devices and the sera magnetic car
lamp. sera responded quickly to the
chemical industry’s rising demand
for dosing and feeding pumps for
acids and was already producing the
first acid pump for Farbwerke Hoechst
in July 1948. sera employee Martin
Hergt’s design principle of the dou-
ble diaphragm pump was patented
in 1950 and is nowadays a globally
recognized technology. This success
proved right for the young business
and from now on it focused on the
development and production of oscil-
lating positive displacement pumps.
In 1958 sera transferred the
design principle of the oscillating
displacement machines to oil-free
compression and pumping of gases
and built the first metal diaphragm
compressor. This laid the foundation
for the division which continues to be
successful to this day — nowadays
as an independent company — sera
ComPress. With more options for
producing tanks, valves and miscel-
laneous fittings now available, sera
SERAGERMANY
engineering for a better world
GEA Tuchenhagen GmbHAm Industriepark 2 – 10, 21514 Büchen, GermanyPhone +49 4155 49-0, [email protected]
GEA Tuchenhagen offers a complete portfolio of normal and self-priming centrifugal pumps – exactly tailored to your needs.
Lowest energy and detergent con sumptionGentle product handling Flow rates from 1 m³/h to 210 m³/hEHEDG certifi ed
Future conveyingHygienic pumps –optimized for effi ciency
p Global 201554
Efficient marathon runners
URACAGERMANY
These high pressure pumps are de-
signed in compliance with API 674
for pumping toxic and flammable
fluids at continuous operation. The
particular advantage of these pumps
is the high and constant volumetric
efficiency allowing economical op-
eration, independent from flow rate
and operating pressure.
The reciprocating pump series
cover a power range
l up to 1,300 kW
l for maximum capacities of
300 m³/h and
l operating pressures of
3,000 bar.
Plunger pumps for the oil & gas
and petrochemical industry can be
used for a variety of applications.
Uraca pumps meet the demands
of typical up and downstream
application features, whether as
hydrostatic test pressure pumps for
pipelines and well service or as in-
jection pumps for salt water, glycol,
methanol and supercritical CO2 and
for wash water and catalysts in the
cracking process.
Process pumps at fluid tempera-
tures of up to 350 °C used for the
gasification process of oil residues
(IGCC) and the coal to liquid process
(coal liquefaction) have long proved
their excellent marathon condi-
tions—25,000 operating hours be-
tween service intervals are not an
exception.
Long-standing life and reliability
are based on an exact design and siz-
ing of pump and components. Uraca
uses pulsation dampers subject to
the reflection principle, so-called
resonators. The dampers are without
internals, which means that they are
maintenance-free, thus exceeding
customer’s expectations by far.
www.uraca.com
Achema: Hall 8.0, E38
kFig. 1 Typical high pressure
injection pump unit with maintenance-free pulsation
dampers as used in oil & gas industry
lFig. 2 High pressure pump
unit P5-96 for coal liquefaction
This YouTube movie describes the
function of a high pressure plunger
pump using a 3D animated model.
It shows an insight into the
mechanics and hydraulics of a
positive displacement pump, starting with the rotation of
the crankshaft and the implementation into an oscillat-
ing motion up to the action of the suction and discharge
valves.
p Info-Plus
This movie describes the functiona -
lity of positioning devices for the
tank cleaning heads for the internal
cleaning of containers and vessels
with high pressure water. Several
positioning systems with varying degrees of automation
are presented.
p Info-Plus
A refurbishment project with German participation in Jordan is aiming at modernizing and thus securing the water
supply for the city of Madaba. One-third of the project fi-nancing was provided by the GIZ (German Society for Inter-national Cooperation) with two-thirds coming from future cost savings. This is made possible by the deployment of efficient pumps from the Dortmund company, Wilo, at the Wala and Libb pump stations.
to be poor. Developing a modern
and futureproof yet affordable water
supply system there calls for innova-
tive solutions. Just how this may be
structured and financed is demon-
strated by the Wala-Libb project, in
which the Dortmund pump manufac-
turer, Wilo, is involved.
Steep wadis hamper infrastructural link-up
Wala and Libb are located in the
mountain region of eastern Jordan,
close to Madaba, the ancient “City of
Mosaics”. l
For many people in Jordan, hav-
ing adequate drinking water is not
something they can take for granted
because the country’s geographi-
cal conditions make extraction im-
mensely difficult. Furthermore, the
country has barely any natural re-
sources and is therefore considered
WILOGERMANY
55p Global 2015
kFig. 1 Foundations and
technology are clearly attacked in the pumping station Wala. Leaks cause water outlet and
corrosion damages. In the past, some of the splitcase and ring
section pumps have been replaced in such a way that the
pipe routing is now unfavourable. The efficiency of the technically
outdated equipment is not higher than 50 to 30 per cent.
The planned modernisation will provide modern pumps
with an efficiency of 75 per cent.
Cost-neutral modernisation
secure water supply in Jordan
Cost-neutral modernisation
secure water supply in Jordan
p Global 201556
There, around 30 kilometres south
of the country’s capital city, Amman,
the landscape is riven by steep-
walled valleys. These so-called
wadis, engraved by riverbeds bear-
ing water only after strong rainfalls,
dissect the tableland on which the
majority of settlements are located.
“That is precisely the problem,” says
Dr. Amer Mokbel, Wilo’s Sales Area
Manager Gulf. “The differences in
altitude between the Jordan Valley
and the tableland can be as much
as 1,400 metres and the ground-
water — the only source of water
in the area — lies very deep in the
WILOGERMANY
earth. Conveying this life-giving
water to the people on the table-
land is therefore a very complicated
matter.”
Altitude of al-together 700 metres overcome to secure water supply
The elevated city of Madaba
is also affected by this difficulty.
Two stages are required in order to
raise the drinking water extracted
at a depth of 250 metres up to the
city. The pump station in Wala, lo-
cated in the valley, transports the
water halfway up the slope to the
Libb pump station from where it is
then conveyed to Madaba. In doing
this, the supply system overcomes
an altitude of 460 metres. “In past
years, outdated, inefficient and
increasingly dilapidated technical
equipment had been causing still
more problems,” Dr. Amer Mokbel
reports. “It was therefore urgently
necessary to upgrade the pumps in
order to ensure that the people of
Madaba were adequately and reli-
ably supplied with water. However,
the Jordan water authority was un-
able to finance this project.” Work-
ing together, three project partners
came up with a way of undertaking
the 440,000 euro upgrade without
equity capital.
Energy saving finances construction project
The financing concept foresees
that one-third of the entire amount
will be provided by the GIZ (Deutsche
Gesellschaft für internationale Zu-
sammenarbeit) from its fund for
Development Partnerships with the
57p Global 2015
spent one year assisting staff at Jor-
dan’s central workshop to draw up
new work plans, optimise processes,
and set up a quality management
system in line with modern stand-
ards. To make these results sustain-
able, the workshop employees were
given comprehensive training. Given
the good working relationship, the
Jordanian Ministry of Water and Ir-
rigation, and the Water Authority
Jordan registered the Dortmund com-
pany as a reliable project partner.
High efficiency helps cut CO2 and costs
Wilo had another opportunity
to work in Jordan in 2009 when the
Water Authority Jordan, which is
responsible for the operation of all
water plant, sought manufacturers
of high-efficiency pumps as part of
a pilot project in conjunction with the
a volume flow of 1400 m³/h. The
aim is to provide Madaba with 7 to
9 million cubic metres of water per
annum.
Quality manage-ment for the central workshop
Wala-Libb is already the third
project that Wilo is undertaking in
Jordan. The company’s good links
with the country were formed in
2006 when the GIZ was looking for
a manufacturer of pressure shroud
pumps as a cooperation partner for
a lengthier assignment in Jordan.
The idea was that repair and servic-
ing plans would be drawn up for all
pumps owned by the state, which
were looked after by the country’s
central workshop. Owing to its long-
standing experience in this area,
Wilo was awarded the contract: Em-
ployees from the German company
project financeable. “Wilo provided
pre-financing of the construction
work for three years,” Dr. Amer Mok-
bel explains. The pump producer is
acting here as a partner of the Jor-
danian consulting engineering main
contractor, Engicon, which handles
many public-sector construction
projects in the water sector. “Engi-
con receives part of the returns from
the energy savings and reimburses
Wilo’s outlay on a six-monthly ba-
sis.” In this way the financing is to
be paid off within three years under
the terms of the contract signed in
December 2013.
The new pumps—high-performing, robust and reliable
The delivery of the pumps,
their installation and their commis-
sioning will take place in April. The
Wala pump station will receive four
pumps, and a further four will be
installed in Libb. Wilo will not only
be delivering the pumps, but will
also oversee their installation and
the start of operations. Furthermore,
employees of the central workshop
in Zarqa—which services and repairs
all of the country’s pumps—will be
trained on the new models. It is not
only their high performance and ef-
ficiency that sets these pumps apart:
because of their robust construction
they can also work reliably under
difficult operating and unfavour-
able climatic conditions. At Wala and
Libb the pumps with output of 315
kilowatts and a maximum delivery
height of 232 metres, will produce
WILOGERMANY
Private Sector. The operator — the
Jordanian water supply company,
Miyahuna — will cover the remaining
two-thirds, solely from the savings
achieved through the efficient opera-
tion of the upgraded plant. This cal-
culation works out thanks to pumps
from manufacturer, Wilo, which use
highly efficient technology. These
modern pump models have an ef-
ficiency factor of up to 75 per cent,
thus far outstripping the old equip-
ment which achieved a factor of 30
to 50 per cent. The resulting reduc-
tion in energy consumption and op-
erating costs makes the high-tech
nFig. 2 The pylons are the first thing that catches ones eye when
overlooking the pumping station in Libb. They guarantee the energy supply of the pumps. The planned modernisation and the utilisation of
efficient Wilo pumps will reduce the electricity consumption of the station significantly. The savings contribute significantly to
financing the renovation measures.
p Global 201558
tions should be completed before
summer so that Madaba’s supply is
secure during the hot season.
www.wilo.com
rity, “even though it is also possible
to finance better quality acquisi-
tions, as Wala-Libb proves.” The
modernisation of the two pump sta-
as “a successful combination of busi-
ness, ecology and help for self-help”
(June 17, 2012).
Quality can be financed as well
The current project in Wala-Libb
continues this excellent working
relationship. “For us it is important
not only to deliver the pumps, but
also to work on achieving an exact
fit for the given use,” says Dr. Amer
Mokbel. “At Wilo we understand
energy efficiency, the responsible
treatment of resources and the
environment, and the development
of innovative concepts. We use this
specialist knowledge to help our
clients find and implement custom-
ised and optimised solutions.” The
Syrian expert also has a personal in-
terest in projects such as Wala-Libb:
“Quality pays for itself. I would like
this to be more broadly recognised
in the countries of the Middle East.”
He says that, too often, people opt
for cheap products that break down
quickly and jeopardize supply secu-
GIZ. The object of the project was to
save energy and reduce CO2 emis-
sions. As Jordan’s biggest consumer
of electricity, the authority, which
uses 15 per cent of the country’s
electricity with its pump operations,
has a very special interest in making
Jordan’s water management system
more eco-friendly and less expen-
sive. The main focus here was on ob-
solete pumps which, in many cases,
had an efficiency factor of only 20 per
cent. Within the scope of the Interna-
tional Climate Protection Initiative,
launched by the Federal Ministry for
the Environment, Nature Conserva-
tion, Building and Nuclear Safety, the
authority contracted Wilo to modern-
ize the Ebquoreyeh pump station.
The manufacturer succeeded in ex-
ceeding the specified targets: Since
then 40 per cent of the electricity
previously required for operation is
now being saved, thanks to the high
efficiency of the Wilo pumps. After
just one year the investment costs of
300,000 euros had been amortised.
The news paper, Westdeutsche Allge-
meine Zeitung, described the project
(DPPs) is one of two strategies with which the GIZ (Deutsche Gesells-
chaft für internationale Zusammenarbeit) is aiming to improve coop-
eration between the private sector, the public sector and civil society
in developing and emerging countries in Africa and Asia. The other
strategy approaches this objective via structure-building capacity
development. The two procedures complement each other: Apart from
the concrete objectives of the respective projects, the Development
Partnerships are also intended to serve as implementation and learn-
ing examples for public-private dialog, and to stimulate ideas.
Development Partnerships with the Private Sector
WILOGERMANY
mFig. 3 The pumps in the pumping station Libb are
controlled via these switch cabinets. It has to be tested whether they can be used in the modernised system.
m
Fig. 4 Dr. Amer Mokbel is Wilo Sales Area Manager for the Gulf area.
The native Syrian takes care of projects in the Middle East from the German company site in Hof.
59p Global 2015
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
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